Truck Refrigeration

Operation and Service Manual

for
Supra 560, 660, 760, 860 & 960
Truck Refrigeration Units

62-11675 Rev D
 Operation and Service Manual
for
Supra 560, 660, 760, 860 & 960
Truck Refrigeration Units

© 2019 Carrier Corporation ● Printed in USA March 2019

 Manual Revision History - 62-11675

Rev. Date Reason for Release

- 05/2013 New product – new manual
A 9/11/14 Print request for 25 manuals by Dan Hayes
B 11/09/15 Updated Book Cover, Book End, safety information. Also, updated CF23 in
configuration code table.
C 06/02/16 Updated Engine model numbers, new oil viscosity, general cleanup.
D 3/11/19 Added section 6.9.2 (Leak Check Using Pressurized Dry Nitrogen)

Change Pages

Date Page Changes

06/13 2-15 Product up-date, 1 setting for all models
08/13 Sec 3, Correction to page numbers
Index
06/14 2-16 Changed Engine Clutch from 40ft-lb to 22ft-lb, request from Vohn
06/14 2-15 Changed CPR setting from 31 psig to 34 psig, request from Joel Dickerson
06/27/14
02/16 6-23 Changed CN4 values for OFF and ON.
 TABLE OF CONTENTS
PARAGRAPH NUMBER PAGE

SAFETY PRECAUTIONS ............................................................... 1–1

1.1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1.1 Automatic Start-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1.2 Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1.3 Refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1.4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.1.5 Standby Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.2 SPECIFIC WARNING, CAUTION, AND NOTICE STATEMENTS ..................... 1–2
1.3 SAFETY DECALS .......................................................... 1–6
UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2.1 INTRODUCTION ........................................................... 2–1
2.2 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.2.1 Road Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.2.2 Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.3 CONDENSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.3.1 Drive Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.3.2 Alternator/Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.3.3 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.3.4 Compressor Unloader (860 and 960 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.3.5 Unloaded Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.3.6 Loaded Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.3.7 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.4 EVAPORATOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.4.1 Thermal Expansion Valve (TXV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.4.2 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.4.3 Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.4.4 Electric and Water Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.5 SYSTEM OPERATING CONTROLS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
2.5.1 Switches And Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
2.6 UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
2.6.1 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
2.6.2 Compressor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
2.6.3 Refrigeration System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
2.6.4 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
2.6.5 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
2.7 SAFETY DEVICES ........................................................ 2–19
2.8 REFRIGERANT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20
2.8.1 Cooling (See Figure 2.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20
2.8.2 Heat And Defrost (See Figure 2.13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
OPERATION ......................................................................... 3–1
3.1 MICROPROCESSOR CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.2 MICROPROCESSOR CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

i 62-11675
 3.3 DESCRIPTION OF MICROPROCESSOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.3.1 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.3.2 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3.4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.4.1 Pre-Trip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.4.2 Starting - Road Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.4.3 Starting - Standby Motor Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.4.4 Pre-Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.4.5 Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.4.6 Start/Stop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
3.4.7 Continuous Run Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
3.4.8 Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
3.4.9 Functional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
3.4.10 Unit Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
3.4.11 Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
CONTROL LOGIC AND TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1 MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.1 Start-up & Pull Down - Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.2 Start-up & Pull Down - Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.3 Null Mode Overrides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.4 Dual Probe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1.5 Fuel Heater Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.6 Defrost Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.7 Unloading in Temperature Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.8 Auto Diesel Restart (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.2 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.2.1 Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.2.2 Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
4.2.3 Auto Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
ALARM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.2 ALARM DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.1 SECTION LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.2 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.3 PRE TRIP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6.4 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
6.5 SERVICING ENGINE RELATED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.5.1 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.5.2 Changing Lube Oil and Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.5.3 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.5.4 Fuel Filter and Fuel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
6.5.5 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.5.6 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7

62-11675 ii
6.6 SERVICING AND ADJUSTING V-BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.6.1 Belt Tension Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.6.2 Alternator V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
6.6.3 Water Pump Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
6.6.4 Standby Motor-Compressor V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
6.6.5 Engine-Compressor V-Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
6.7 INSTALLING MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
6.7.1 Preparing Manifold Gauge/Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
6.7.2 Connecting Manifold Gauge/Hose Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
6.7.3 Removing the Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
6.8 PUMPING THE UNIT DOWN OR REMOVING THE REFRIGERANT CHARGE . . . . . . . . . 6–13
6.8.1 Pumping the Unit Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
6.8.2 Removing the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
6.9 REFRIGERANT LEAK CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
6.9.1 Standard Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
6.9.2 Leak Check Using Pressurized Dry Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
6.10 EVACUATION AND DEHYDRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
6.10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
6.10.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
6.10.3 Evacuation and Dehydrating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
6.10.4 Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
6.10.5 Installing a Complete Charge (See Figure 6.11) . . . . . . . . . . . . . . . . . . . . . . . . 6–17
6.10.6 Adding A Partial Charge (See Figure 6.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–19
6.11 REPLACING THE COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
6.11.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
6.11.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
6.12 COMPRESSOR OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
6.12.1 Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
6.12.2 Adding Oil with Compressor in System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
6.12.3 Adding Oil to Service Replacement Compressor . . . . . . . . . . . . . . . . . . . . . . . . 6–21
6.12.4 Remove oil from the compressor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–21
6.13 COMPRESSOR UNLOADER VALVE (860 AND 960 ONLY) . . . . . . . . . . . . . . . . . . . . . . . . 6–21
6.13.1 Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–21
6.13.2 Solenoid Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–22
6.13.3 Replacing Solenoid Valve Internal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–22
6.14 CHECKING & REPLACING FILTER-DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–22
6.15 CHECKING & REPLACING HIGH PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–22
6.15.1 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–22
6.15.2 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–23
6.16 CHECKING CALIBRATION OF THE DEFROST AIR SWITCH ...................... 6–23
6.17 EVAPORATOR COIL CLEANING ............................................. 6–24
6.18 CONDENSER COIL CLEANING .............................................. 6–24
6.19 SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24
6.19.1 Supra 560/660/760/860/960 3-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24
6.19.2 Hot Gas Bypass Valve (HGS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25
6.20 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE (CPR) . . . . . . . . . . 6–25
6.21 THERMAL EXPANSION VALVE (TXV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26
6.22 MICROPROCESSOR CONTROLLER ......................................... 6–27

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 6.23 MICROPROCESSOR REPLACEMENT & CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . 6–27
6.23.1 Remove & Replace Microprocessor Logic Board . . . . . . . . . . . . . . . . . . . . . . . . 6–27
6.23.2 Reach The Configuration Fields From Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28
6.24 CONTROLLER SENSOR CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28
6.25 SUCTION PRESSURE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–31
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
7.1 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
7.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
7.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
7.1.3 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
7.1.4 Malfunction In the Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
7.2 ALTERNATOR (AUTOMOTIVE TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
7.3 REFRIGERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.3.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.3.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.3.3 Unit Operates Long or Continuously in Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.3.4 Unit Will Not Heat or Has Insufficient Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.3.5 Defrost Cycle Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.3.6 Abnormal Pressure, Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.3.7 Abnormal Pressure, Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.3.8 Abnormal Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.3.9 Control System Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.3.10 No Evaporator Air Flow or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.3.11 Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.3.12 Hot Gas (3-Way) Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.4 STANDBY MOTOR MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
ELECTRICAL SCHEMATIC WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
8.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
8.2 WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

62-11675 iv
 SECTION 1
Safety Precautions

1.1 Safety Precautions

Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind. During normal
operation, all moving parts are fully enclosed to help prevent injury. During all pre-trip inspections, daily inspec-
tions, and problem troubleshooting, you may be exposed to moving parts. Please stay clear of all moving parts
when the unit is in operation and when the Main Power switch is not in the OFF position.

NOTICE
Under no circumstances should a technician electrically probe the microprocessor at any
point, other than the connector terminals where the harness attaches. Microprocessor compo-
nents operate at different voltage levels and at extremely low current levels. Improper use of
voltmeters, jumper wires, continuity testers, etc. could permanently damage the microproces-
sor.

NOTICE
Most electronic components are susceptible to damage caused by electrical static discharge
(ESD). In certain cases, the human body can have enough static electricity to cause resultant
damage to the components by touch. This is especially true of the integrated circuits found on
the microprocessor.

1.1.1 Automatic Start-Stop

Your refrigeration unit is equipped with auto-start in both Start-Stop and Continuous Operation. The unit may start
at any time the Main Power switch is not in the OFF position. A buzzer will sound for 5 seconds before the unit is
started. When performing any check of the refrigeration unit (e.g., checking the belt, checking the oil), make certain
that the Main Power switch is in the OFF position.

1.1.2 Engine Coolant

The engine is equipped with a pressurized cooling system including a pressurized coolant bottle. Under normal
operating conditions, the coolant in the engine and radiator is under high pressure and is very hot. Contact with hot
coolant can cause severe burns. Do not remove the cap from a hot radiator or bottle. If the cap must be removed,
cover it with a rag and remove very slowly in order to release the pressure without spray.

1.1.3 Refrigerants
The refrigerant contained in the refrigeration system of this unit can cause frostbite, severe burns, or blindness
when in direct contact with the skin or eyes. For this reason (and because of legislation regarding the handling of
refrigerants) we recommend that you contact your nearest Carrier Transicold authorized repair facility whenever
service of the refrigerant system is required.

1.1.4 Battery
This unit is equipped with a lead-acid type battery. The battery normally vents small amounts of flammable hydro-
gen gas. Do not smoke when checking the battery. A battery explosion can cause serious physical harm and/or
blindness.

1.1.5 Standby Power

Be aware of HIGH VOLTAGE supplied at the power plug. Even with the unit off, power is present from the plug to
the inside of the control box. Whenever practical, disconnect the high voltage source when performing service or
maintenance procedures and lockout/tagout the receptacle in accordance with your companies procedures.

1-1 62-11675
1.2 Specific Warning, Caution, and Notice Statements
To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation is
given with the appropriate consequences:

! DANGER
DANGER − warns against an immediate hazard which WILL result in severe personal injury or death.

! WARNING
WARNING − warns against hazards or unsafe conditions which COULD result in severe personal
injury or death.

! CAUTION
CAUTION − warns against potential hazard or unsafe practices which could result in minor personal
injury.

NOTICE
NOTICE − warns against potential product or property damage.

The statements listed below are specifically applicable to this refrigeration unit and appear elsewhere in this man-
ual. These recommended precautions must be understood and applied during operation and maintenance of the
equipment covered herein.

! WARNING
Unit may start automatically at any time even if the switch is in the OFF position. Use proper
lockout/tagout procedures before inspection/servicing. All unit inspection/servicing by prop-
erly trained personnel only.

! WARNING
Beware of unannounced starting of the engine, standby motor, evaporator fan or condenser
fan. The unit may cycle the engine, standby motor or fans unexpectedly as control require-
ments dictate.

! WARNING
Under no circumstances should ether or any other starting aids be used to start the engine.

! WARNING
Make sure the power plug is clean and dry before connecting to any power source.

! WARNING
Do not attempt to connect or remove power plug or perform service and/or maintenance before
ensuring the unit RUN/STOP Switch is in the STOP position, and the I/O switch is in the “O”
position.

62-11675 1-2
 ! WARNING
Advance microprocessor equipped units may start automatically at any time the Main Power
switch is not in the OFF position. Also, the unit may be fitted with two way communication
equipment that will allow starting of the unit from a remote location even though the switch is
in the OFF position.

! WARNING
Be aware of HIGH VOLTAGE supplied at the power plug or from the generator. When perform-
ing service or maintenance procedures: ensure any two way communication is disabled in
accordance with the manufacturer’s instructions, ensure the Main Power switch is in the OFF
position and, whenever practical, disconnect the high voltage source, lockout/tagout the
receptacle and disconnect the negative battery connection. NEVER dis-assemble the genera-
tor: HIGH MAGNETIC FIELD INSIDE! This field can interfere with cardiac implants such as
pacemakers and defibrillators.

! WARNING
Beware of V-belts and belt driven components as the unit may start automatically. Before ser-
vicing unit, make sure the RUN/STOP Switch is in the STOP position. Also disconnect the neg-
ative battery cable.

! WARNING
Beware of V-belts and belt driven components as the unit may start automatically.

! WARNING
Ensure power to the unit is OFF and power plug is disconnected or vehicle engine is OFF and
negative battery cable is disconnected before replacing the compressor.

! WARNING
Since refrigerant traps a certain quantity of oil, to avoid oil loss during maintenance, add 50 cc
of POE oil to the refrigeration system when any evacuation is performed.

! WARNING
Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approxi-
mately 2350 psi (165 kg/cm2). Do not use oxygen in or near a refrigerant system as an explo-
sion may occur. (Figure 6.15)

! WARNING
Beware of unannounced starting of the fans and V-belts caused by the thermostat and the
start/stop cycling of the unit.

1-3 62-11675
 ! CAUTION
Observe proper polarity when installing the battery. The negative battery terminal must be
grounded. Reverse polarity will destroy the rectifier diodes in the alternator. As a precaution-
ary measure, disconnect positive battery terminal when charging battery in unit. Connecting
charger in reverse will destroy the rectifier diodes in alternator.

! CAUTION
Under no circumstances should anyone attempt to repair the Logic or Display Boards. Should
a problem develop with these components, contact your nearest Carrier Transicold dealer for
replacement.

! CAUTION
Unit uses R-404a and POE oil. The use of inert gas brazing procedures is mandatory for all
Carrier Transicold refrigeration units; otherwise compressor failure will occur. For more infor-
mation Refer to Technical Procedure 98-50553-00 Inert Gas Brazing.

! CAUTION
Use only ethylene glycol anti-freeze (with inhibitors) in system as glycol by itself will damage
the cooling system. Always add pre-mixed 50/50 anti-freeze and water to radiator/engine.
Never exceed more than a 50% concentration of antifreeze. Use a low silicate anti-freeze.

! CAUTION
When changing the oil filter, the new filter should be primed with clean oil. If the filter is not
primed, the engine may operate for a period with no oil supplied to the bearings.

! CAUTION
When changing the fuel filter, the new filter should be filled with clean fuel.

! CAUTION
Observe proper polarity, reverse polarity will destroy the diodes. As a precaution, disconnect
positive terminal when charging.

! CAUTION
To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suc-
tion pressure before disconnecting.

! CAUTION
Refrigerant R-404a is a blend. Charging as a vapor will change the properties of the refrigerant.
Only liquid charging through the receiver service valve is acceptable.

62-11675 1-4
 ! CAUTION
Extreme care must be taken to ensure the manifold common connection remains immersed in
oil at all times. Otherwise air and moisture will be drawn into the compressor.

! CAUTION
Do not damage or over tighten the enclosing tube assembly. Also make sure all parts are
placed on the enclosing tube in proper sequence to avoid premature coil burnout.

! CAUTION
DO NOT attempt to service the microprocessor or the logic or display boards! Should a prob-
lem develop with the microprocessor, contact your nearest Carrier Transicold dealer for
replacement.

! CAUTION
Under no circumstances should anyone attempt to repair the Logic or Display Boards! Should
a problem develop with these components, contact your nearest Carrier Transicold dealer for
replacement.

! CAUTION
Observe proper polarity when installing the battery. The negative battery terminal must be
grounded. Reverse polarity will destroy the rectifier diodes in the alternator. As a precaution-
ary measure, disconnect positive battery terminal when charging battery in unit. Connecting
charger in reverse will destroy the rectifier diodes in alternator.

NOTICE
Under no circumstances should a technician electrically probe the processor at any point,
other than the connector terminals where the harness attaches. Microprocessor components
operate at different voltage levels and at extremely low current levels. Improper use of voltme-
ters, jumper wires, continuity testers, etc. could permanently damage the processor.

NOTICE
Most electronic components are susceptible to damage caused by electrical static discharge
(ESD). In certain cases, the human body can have enough static electricity to cause resultant
damage to the components by touch. This is especially true of the integrated circuits found on
the truck/trailer microprocessor.

1-5 62-11675
1.3 Safety Decals

62-11675 1-6
1-7 62-11675
62-11675 1-8
 SECTION 2
Unit Description
2.1 Introduction This manual contains operating data, electrical data and
service instructions for the Carrier Transicold Supra
model truck refrigeration units listed in Table 2–1.
! WARNING Additional Supra support manuals are listed in Table
Beware of unannounced starting of the 2–2.
engine, standby motor, evaporator fan or The model/serial number plate is located inside the unit
condenser fan. The unit may cycle the on the frame as shown in Figure 2.2.
engine, standby motor or fans unexpect-
edly as control requirements dictate.

Table 2–1 Model Chart

REFRIGERANT STANDBY
MODEL R-404A ENGINE COMPRESSOR MOTOR

LB KG 60 Hz

Supra 560, TDB-13 5.9 hp

9 4 Z482
Supra 560, TDS-13 (4.4 kW)

Supra 660, TDB-16 05K 012

Supra 660, TDS-16 2 Cylinder
7.6 hp
13 5.9
Supra 760, TDB-19 (5.7 kW)
D722
Supra 760, TDS-19

Supra 860, TDB-24 05K 024 8.3 hp

Supra 860, TDS-24 4 Cylinder (6.2 kW)
15 6.8
Supra 960, TDB-36 05G37 14.8 hp
D1105
Supra 960, TDS-36 6 Cylinder (11 kW)

Table 2–2 Additional Support Manuals

Manual Number Equipment Covered Type of Manual

62-11369 Supra (All) Parts Look Up System (PLUS)

62-11681 Supra 60 Series Easy to Run

62-11674 Supra 60 Series Operator's Manual

62-02491 Compressor (05K012) Operation and Service

62-02460 Compressor (05K4) Parts List

62-02756 Compressor (05G) Operation and Service

62-11052 Compressor (05G Twin port) Operation and Service

62-10299 Compressor (05G) Parts List

62-11053 Compressor (05G Twin port) Parts List

2-1 62-11675
 Figure 2.1 Condensing Section - Top View/Cab Command
1 2 3 4 5 6 7 8 9 10 11

16 15 14 13 12

ALARM/FAULT

-20 35 F i
UNIT DATA

SETPOINT BOX TEMPERATURE

FUNCTION ENTER
AUTO START/STOP

PRETRIP

O
O I

ROAD CITY MAN BUZZER OFF STANDBY

SPEED DEFROST

Cab Command

1. Muffler 9. Compressor Pressure Regulating Valve (CPR)

2. Thermal Expansion Valve (Location) 10. Accumulator
3. Engine (Refer to Table 2–1) 11. Filter Drier
4. Heat Exchanger (Location) 12. Receiver
5. Compressor 13. Hot Gas Bypass Solenoid (HGS2)
6. Alternator 14. Hot Gas 3-Way Valve (HGS1)
7. Electric Standby Motor 15. Condenser
8. Defrost Air Switch 16. Radiator Overflow Reservoir

62-11675 2-2
 Figure 2.2 Unit Curbside View

3
1. Fuel Filter 4. Engine Oil filter (behind fuel filter)
2. Model/Serial Number Plate 5. Engine Oil Dip Stick
3. Speed and Run Solenoids 6. Air Cleaner
-----

Figure 2.3 Unit Roadside View

2
1

4 5 6
3

1. Receiver Sight Glasses 4. Relay/Fuse Board

2. Electrical Box (See Figure 2.4) 5. Standby Motor Control
3. Microprocessor Board 6. RUN/STOP Switch (RSS)

2-3 62-11675
 Figure 2.4 Electrical Box

4 9

6 7

1. Manual RUN/STOP Switch 6. Relay/Fuse Board (See Figure 2–11, Figure 2.5)
2. Warning Buzzer 7. Motor Overload Relay (MOL)
3. Summer/Winter Switch (EWHS Only) 8. Standby Motor Contactor (MC)
4. Fuel Heater Relay (FHR - Option) 9. Microprocessor Module
5. Main Fuse (F1, 80 amp)

NOTE
See Figure 3.1 for Cab Command

62-11675 2-4
 Figure 2.5 Relay/Fuse Board (With All Optional Components)

FHR
Table 2–3 Fuse Identification Table 2–4 Relay Identification

Desig. Item Amps Desig. Item

F1 Main Fuse 80A SSR Starter Solenoid Relay

F2 RCR Fuse 5A EFMR1 Electric Fan Motor Relay

F3 Run Relay Fuse 15A EFMR2 Electric Fan Motor Relay

F4 Heat Relay Fuse 3A EFMR3 Electric Fan Motor Relay

F5 Speed Relay Fuse 10A DDR Defrost Damper Solenoid Relay (Option)

F6 Unloader Fuse (860 & 960) 5A UFR Unloader Front Relay (860 & 960)

F7 Defrost Damper Relay Fuse 15A CCR Compressor Clutch Relay

(Option) (960 Only)
SR Speed Relay
F8 Electric Fan Motor Fuse 20A
HR1 Heat Relay 1
F9 Electric Fan Motor Fuse 20A
DER Diesel Electric Relay
F10 Electric Fan Motor Fuse 20A
RR Run Relay
F11 Fuel Pump Fuse 5A
GPR Glow Plug Relay
F12 Fuel Heater Fuse (Option) 25A
RCR Run Control Relay

EHR Evaporator Heater Relay

FHR Fuel Heater Relay (Optional)

2-5 62-11675
 Table 2–5 Test Point Identification 2.2 General Description

Test Point # Circuit The Supra models are self contained one-piece refrig-
eration/heating units designed for truck applications.
TP1 RR NO Output The units consist of a condenser section, located out-
side the truck body, and an evaporator section which
TP2 DER NO Output extends inside the body. Two types of drives may be
TP3 F11 Output included.

TP4 DER NC Output 2.2.1 Road Operation

TP5 EHR NO Output Both the TDB and TDS model units are equipped with
an engine. In the Road Operation mode, the compres-
TP6 SSR NO Output sor and alternator are driven by the engine. TDB units
do not have standby motors. A standby motor shell is
TP7 GPR NO Output installed (without the motor winding) to allow the same
TP8 HR1 NO Output belt arrangement for both units.

TP9 SR NO Output 2.2.2 Standby Operation

TP10 UFR NO Output TDS units are equipped with an internal combustion
diesel engine and an electric standby motor. In Standby
TP11 CCR NO Output Operation, the compressor and alternator are driven by
the electric standby motor.
TP12 DDR NO Output

TP13 EFMR1 NO Output

TP14 EFMR2 NO Output

TP15 EFMR3 NO Output

TP16 RCR NO Output

TP17 DPS 12 Volt Input

62-11675 2-6
2.3 Condensing Section unit. Connecting charger in reverse will
destroy the rectifier diodes in alternator.
The condensing section (see Figure 2.1, Figure 2.2 &
Figure 2.3) contains the drive equipment, alternator The alternator supplies power for operation of the sys-
and the high side refrigeration system equipment. The tem controls, evaporator fan motors and for charging of
engine radiator and refrigerant condenser are incorpo- the unit battery, if equipped.
rated into a single condenser/radiator assembly.
The alternator converts mechanical and magnetic
2.3.1 Drive Equipment energy to alternating current (AC) and voltage, by the
rotation of an electromagnetic field (rotor) inside a
The drive equipment includes the engine, engine three phase stator assembly. The alternating current
mounted clutch, air cleaner, muffler, coolant overflow and voltage is changed to direct current and voltage, by
bottle, drive belts and standby motor. passing AC energy through a three phase, full wave
rectifier system. Six silicon rectifier diodes are used.
2.3.1.1 Engine
The engine (Figure 2.1) is a TriVortex diesel The voltage regulator is an all electronic, transistorized
manufactured by Kubota. Engine operation is switching device, integral to the alternator. It senses
controlled by a Run Solenoid and a Speed the voltage appearing at the auxiliary terminal of the
Solenoid. The engine is cooled by a radiator alternator and supplies the necessary field current for
which is integral with the refrigerant condenser. maintaining the system voltage at the output terminal.
The cooling system is fitted with a coolant The electronic circuitry should never require adjust-
overflow reservoir. Engine air cleaners are dry ment and the solid state active elements used have
type. proved reliable enough to warrant a sealed unit.

2.3.1.2 Clutch Assembly 2.3.3 Compressor

The clutch assembly is mounted on the engine The compressor assembly includes the refrigerant
crankshaft. All units have centrifugal type compressor, suction and discharge service valves, high
clutches. pressure switch, unloader (860 and 960 only) and the
suction pressure transducer. The compressor draws
2.3.1.3 Standby Motor refrigerant gas from the evaporator and delivers it to
The standby motor operates on nominal 460v- the condenser at an increased pressure. The pressure
3ph-60Hz or 230v-3ph-60Hz power. An over- is such that refrigerant heat can be absorbed by the
load and short cycle protection is provided surrounding air at ordinary temperatures.
along with automatic reset. Units are also
2.3.4 Compressor Unloader (860 and 960 Only)
equipped with a remote mounted power recep-
tacle. (Refer to Section 4.1.7 for detailed information on
unloader temperature control.)
2.3.2 Alternator/Regulator
The Supra 860 and 960 unit compressors are fitted
with one electric unloader valve. The capacity con-
! CAUTION trolled cylinder is easily identified by the solenoid which
extends from the side of the cylinder head. When the
Observe proper polarity when installing solenoid is energized two cylinders are unloaded. The
battery, negative battery terminal must be unloaded cylinders operate with little or no pressure dif-
grounded. Reverse polarity will destroy ferential, consuming very little power.
the rectifier diodes in alternator. As a pre-
cautionary measure, disconnect positive A description of unloader operation is provided in the
battery terminal when charging battery in following steps.

2-7 62-11675
 Figure 2.6 Compressor Cylinder Head Unloaded

2
1 3 7
45
6

8
11
9

15

14 10

12

13

1. Solenoid Valve 9. Strainer

2. Valve Stem 10. Suction Manifold
3. Gas Bypass Port 11. Cylinder Discharge Valve
4. Spring Guide 12. Valve Plate
5. Spring 13. Cylinder Suction Valve
6. Piston 14. Discharge Check Valve Assembly
7. Bypass Valve 15. Discharge Manifold
8. Bleed Orifice

2.3.5 Unloaded Operation When the pressure behind the piston has been
reduced sufficiently, the valve spring will force the pis-
Pressure from the discharge manifold (item 15, Figure
ton back, opening the gas bypass from the discharge
2.6) passes through the strainer (9) and bleed orifice
manifold to the suction manifold.
(8) to the back of the bypass valve piston (6). Unless
bled away, this pressure would tend to close the piston Discharge pressure in the discharge manifold will close
against the spring (5) pressure and load the cylinders the discharge piston check valve assembly (14) isolat-
in that head. ing the compressor discharge manifold from the indi-
vidual cylinder bank manifold.
With the solenoid valve (1) energized, the solenoid
valve stem (2) will open the gas bypass port (3). The unloaded cylinder bank will continue to operate
fully unloaded until the solenoid valve is de-energized
Discharge pressure will be bled to the suction manifold
and the gas bypass port is closed.
(10) through the opened gas bypass port. A reduction
in pressure on the bypass piston valve will take place
because the rate of bleed through the gas bypass port
is greater than the rate of bleed through the bleed ori-
fice (8).

62-11675 2-8
 Figure 2.7 Compressor Cylinder Head Loaded

1 3 7
45
6

8
11
9

15

14
10

12

13

1. Solenoid Valve 9. Strainer

2. Valve Stem 10. Suction Manifold
3. Gas Bypass Port 11. Cylinder Discharge Valve
4. Spring Guide 12. Valve Plate
5. Spring 13. Cylinder Suction Valve
6. Piston 14. Discharge Check Valve Assembly
7. Bypass Valve 15. Discharge Manifold
8. Bleed Orifice

2.3.6 Loaded Operation

With the solenoid valve (1, Figure 2.7) de-energized, Cylinder discharge pressure will force the discharge
the solenoid valve stem will close the gas bypass port check valve assembly (14) open. Refrigerant gas will
(3). then flow into the compressor discharge manifold.
Pressure from the discharge manifold (15) through the The loaded cylinder bank will continue to operate fully
strainer (9) and bleed orifice (8) will build behind the loaded until the solenoid valve is energized and the
piston (6). gas bypass port is opened.
This increased pressure will overcome the bypass
valve spring (5) tension and force the piston (6) forward
closing the gas bypass from the discharge manifold to
the suction manifold (10).

2-9 62-11675
2.3.7 Refrigeration System 2.3.7.4 Hot Gas 3-Way Valve (HGS1)
The condensing section mounted refrigeration system The Hot Gas 3-Way Valve (HGS1) directs flow of refrig-
equipment includes the compressor, condenser/sub- erant through the system. With the solenoid coil de-
cooler, accumulator, defrost air switch, filter drier, energized the valve is in the cool mode and the com-
receiver, hot gas (three way) valve, hot gas bypass pressor discharge gas is delivered to the condenser. In
valve (except for 960) and compressor pressure regu- the cool mode, heat is removed from the air inside the
lating valve. truck body and rejected to the surrounding air. With the
solenoid coil energized the valve is in the heat mode
2.3.7.1 Condenser/Subcooler and the compressor discharge gas is diverted to the
The condenser is of the tube and fin type and acts as a evaporator. In the heat mode, heat is removed from the
heat exchanger in which the compressed refrigerant air surrounding the truck body and rejected to the air
gas is condensed into a liquid and lowered in tempera- inside the truck body. A description of valve operation
ture. Air movement over the condenser is provided by is provided in the following sub-paragraphs.
a fan mounted on the standby motor/motor shell shaft.
2.3.7.5 Cooling Operation (See Figure 2.9)
A portion of the condenser is occupied by the sub- With the solenoid coil de-energized, the valve is in the
cooler. Refrigerant leaving the receiver is passed cool operating mode and the refrigerant gas is diverted
through the subcooler where additional heat is to the condenser. The volume directly above the piston
removed. Removal of this additional heat helps to assembly is open to suction pressure through the
ensure that only liquid refrigerant enters the thermal external pilot connection and the volume underneath
expansion valve. the piston assembly is open to discharge pressure
through the compressor discharge connection. This dif-
2.3.7.2 Accumulator
ference in pressure across the piston assembly results
The accumulator is a refrigerant holding tank located in in the piston assembly being shifted upward, shutting
the suction line between the evaporator and compres- the heat and defrost port, opening the condenser port,
sor. The purpose of the accumulator is to prevent entry and allowing refrigerant to flow to the condenser.
of any liquid refrigerant into the compressor.
Refrigerant vapor leaves the accumulator outlet pipe at
a point well above any liquid level thus preventing the
entrance of liquid. The outlet pipe is equipped with an Figure 2.9 Hot Gas 3-Way Valve (HGS1) - Cooling
orifice that controls oil return to the compressor and Flow
prevents accumulation of oil within the tank.
To Compressor
Figure 2.8 Accumulator Suction
To compressor suction

From
evaporator
Solenoid
De-Energized To Evaporator

Oil return orifice

From
Compressor

2.3.7.3 Compressor Pressure Regulating Valve

(CPR)
This adjustable regulating valve regulates the suction
To Condenser
pressure entering the compressor. The suction pressure
is controlled to avoid overloading the electric motor or
engine during high box temperature operation.

62-11675 2-10
2.3.7.6 Heat and Defrost Operation (See Figure refrigerant. A sight glass may also be installed down-
2.10) stream of the drier. The sight glass is fitted with a paper
When the hot gas solenoid coil is energized, discharge element that changes color to indicate moisture content.
gas flows to the evaporator for heating or defrost.
2.3.7.9 Receiver
When energized, the solenoid plunger is lifted, allowing
discharge gas to fill the volume above the piston Liquid refrigerant from the condenser drains into the
assembly. Discharge gas is also allowed to fill the vol- receiver. The receiver serves as a liquid reservoir when
ume below the piston assembly through the compres- there are surges due to load changes in the system; as
sor discharge connection. The pressure on both sides a storage space when pumping down the system and
of the piston assembly is now equal and the piston as a liquid seal against the entrance of refrigerant gas
spring exerts a force on top of the piston assembly and into the liquid line.
shifts it downward. The condenser port is now closed The receiver is provided with two bullseye sight
and the evaporator port is open. In both the energized glasses, for the observation of liquid level, and a pres-
and de-energized positions, the bypass of discharge sure relief valve.
gas to the suction port is prevented.
2.4 Evaporator Section
Figure 2.10 Hot Gas 3-Way Valve (HGS1) Heat &
Defrost Flow The evaporator section contains the evaporator coil,
expansion valve (TXV), heat exchanger, defrost termi-
nation thermostat(s) and electrical evaporator fan
motors.

2.4.1 Thermal Expansion Valve (TXV)

The thermal expansion valve is an automatic device
which controls the flow of liquid to the evaporator
according to changes in superheat to the refrigerant
Solenoid leaving the evaporator. The thermal expansion valve
Energized maintains a relatively constant degree of superheat in
the gas leaving the evaporator regardless of suction
To Evaporator
pressure. Thus, the valve has a dual function; auto-
From matic expansion control and prevention of liquid return
Compressor to the compressor.

2.4.2 Heat Exchanger

The heat exchanger is of the tube in tube type con-
nected in the main suction line and liquid line. Within
To Condenser
the heat exchanger, the cold suction gas is used to cool
the warm liquid refrigerant. This results in greater sys-
tem capacity and efficiency.
2.3.7.7 Hot Gas Bypass Solenoid Valve (HGS2) 2.4.3 Evaporator Coil
(except 960)
The evaporator coil is a tube and fin type. The opera-
The hot gas bypass solenoid valve (HGS2) opens tion of the compressor maintains a reduced pressure
during heating and allows the compressor to draw with the coil. At this reduced pressure, the liquid refrig-
vapor from the top of the receiver resulting in increased erant evaporates at a temperature sufficiently low
heating capacity. enough to absorb heat from the air. Air movement over
the condenser is provided by two or three electric fans.
2.3.7.8 Filter Drier
2.4.4 Electric and Water Heat
The drier is cylinder shell containing a drying agent and
screen. It is installed in the liquid line and functions to The unit can be equipped with Electric Heat, Water
keep the system clean and remove moisture from the Heat, and Electric/Water heat. See Figure 2.11. When
the controller calls for heat, the heater contactor will
close or valve will open and engage the heat system.

2-11 62-11675
 Figure 2.11 Water and Electric Heat Components

Water Heat Coil

Electric
2 Heat
Elements

1
Hot Water Heat Components
1. Water Valve
2. Water Tube (HWH)
3. Hose (HWH)
Unit Control Box 4. Harness (HWH)

2.5 System Operating Controls and Components 2.5.1.1 RUN/STOP Switch (RSS)
The unit is furnished with a microprocessor control sys- This switch controls the supply of power to the micro-
tem. Once the set point is entered at the controller, the processor and cab command. The switch is placed in
unit will operate automatically to maintain the desired the ON position to allow manual or automatic unit oper-
temperature within very close limits. The control sys- ation. With the switch in the OFF position, the unit will
tem automatically selects high and low speed cooling be shut down and neither manual or automatic starting
or high and low speed heating as necessary to main- is allowed.
tain the desired temperature.
2.5.1.2 Oil Pressure Safety Switch (OP)
Units also have a auto start/stop feature. Auto start/
This switch will automatically stop the engine upon loss
stop operation provides automatic cycling of the diesel
of oil pressure. The switch is located on the side of the
engine or standby motor, which in turn offers an energy
engine.
efficient alternative to continuous operation.
2.5.1.3 Water Temperature Sensor (WTS)
2.5.1 Switches And Controls
The microprocessor will stop the unit when this sensor
Manual control switches are located on the side of the
signals a high water temperature condition. The sensor
electrical box. Components required for monitoring and
is located on the engine cylinder head.
controlling the diesel engine and refrigeration system
are located on the engine, compressor or system piping.

62-11675 2-12
2.5.1.4 High Pressure Cutout Switch (HP1) sively low suction pressure conditions. The sensor is
located on the compressor body for all units except
This switch will automatically stop the engine when 860. It is located in the suction line for 860 units.
compressor discharge pressure exceeds the set point.
The switch is located on the compressor cylinder head. 3. Ambient Temperature Sensor (ATS) (960 Only)
The Ambient Temperature Sensor signal is used by the
2.5.1.5 High Pressure Switch (HP2) (860 Only)
microprocessor in the compressor protection logic to
This switch is used to activate the compressor determine expected conditions. It is located between
unloader in high ambient conditions. the condenser and the front grille.
1. Compressor Discharge Temperature Sensor (CDT) 4. Temperature control sensors
(except for 860)
Box temperature is controlled by one or two sensors:
The microprocessor will stop the unit when this sensor • RAS: Measures return air to the evaporator
signals a high discharge temperature condition. The
sensor is located on the compressor center head. • SAS (optional): Measures supply air to the evap-
2. Compressor Suction Pressure Transducer (SPT) orator and is also used in heat option kits as an
over temperature safety sensor.
The Compressor Suction Pressure Transducer signal
is used by the microprocessor in the compressor pro-
tection logic to protect the compressor from exces-

2.6 Unit Specifications

2.6.1 Engine Data

Lube Oil Viscosity: (API Classification CD)

Table 2–6 Lube Oil Viscosity

Outdoor Temperature Recommended Oils
Below 32°F or 0°C 10W30, 5W40 (synthetic)
Above 32°F or 0°C 10W30, 5W40 (synthetic), 15W40

Ambient Temperature
O O
0C 40 C
O O
32 F 104 F
10W30*
5W40* (synthetic)
15W40**
*10W30 & 5W40 (synthetic) are recommended for ALL climates
o o
**15W40 is NOT recommended for climates < 32 F (0 C)

2-13 62-11675
 Table 2–7 Engine Data For Supra 560

Engine Model Z482

Displacement 29.2 in3 (479 cc)

No. Cylinders 2

Horsepower 8.5 hp (6.3 kW) @2400rpm

Weight 117 lbs (53 kg)

4.0 quarts (3.8 liters) - Without EWHS

4.5 quarts (4.3 liters) - With EWHS

Coolant Capacity
Use 50/50 to 60/40 ethylene glycol/water mix, standard or Shell Dexcool
extended life antifreeze

Oil Capacity 5.85 quarts (5.5 liters)

Operating High 2300 - 2350 rpm

Speeds Low 1800 to 1850 rpm

Injection Setting 1991 to 2133 psig (135 to 145 bar)

Oil Pressure Switch Closes at: 18 ± 3 psig (1.2 ± 0.2 bar)

Glow Plug 0.9 ohms at 11 volts

Closes on temperature falls at 45 ± 6.5°F (7.2 ± 1.17°C)

Fuel Heater Thermostat
Opens on temperature rise at 75 ± 6.5°F (24 ± 1.17°C)

Table 2–8 Engine Data For Supra 660/760/860

Engine Model D722

Displacement 43.9 in3 (719 cc)

No. Cylinders 3

Horsepower 15.5 hp (11.6 kW) @2400rpm

Weight 139 lbs (63 kg)

3.9 quarts (3.7 liters) - Without EWHS

4.5 quarts (4.3 liters) - With EWHS

Coolant Capacity
Use 50/50 to 60/40 ethylene glycol/water mix, standard or extended
life antifreeze

Oil Capacity 8.4 U.S. quarts (8 liters)

660: 2200 to 2250 rpm

Operating High 760: 2400 to 2450 rpm
Speeds 860: 2300 to 2350 rpm

Low 1800 to 1850 rpm

Injection Setting 1991 to 2133 psi (135 to 145 bar)

Oil Pressure Switch Closes at: 18 ± 3 psig (1.22 ± 0.2 bar)

Glow Plug 1.4 ohms at 11 volts.

Fuel Heater Closes on temperature falls at 45 ± 6.5°F (7.2°± 1.17°C)

Thermostat Opens on temperature rise at: 75 ± 6.5°F (24 ± 1.17°C)

62-11675 2-14
 Table 2–9 Engine Data For Supra 960

Engine Model D1105

Displacement 68.5 in3 (1123 cc)

No. Cylinders 3

Horsepower 20hp (14.9kW) @ 2400rpm

Weight 214 lbs (97 kg)

5 quarts (4.7 liters)

Coolant Capacity Use 50/50 to 60/40 ethylene glycol/water mix, standard or extended
life antifreeze

Oil Capacity 10 quarts (9.46 liters)

Operating High 2200 to 2250 rpm

Speeds Low 1800 to 1850 rpm

Injection Setting 1991 to 2133 psi (135 to 145 bar)

Oil Pressure Switch Closes at: 18 ± 3 psig (1.2 ± 0.2 bar)

Glow Plug 0.9 ohms at 11 volts.

Fuel Heater Closes on temperature falls at 45 ± 6.5°F (7.2 ± 1.17°C)

Thermostat Opens on temperature rise at: 75 ± 6.5°F (24 ± 1.17°C)

2-15 62-11675
2.6.2 Compressor Data
Table 2–10 Compressor Data

Model (Unit) 05K 012 (560/660/760) 05K 024 (860) 05G37 (960)

Displacement 12.2 in3 (200 cc) 24.4 in3 (400 cc) 37 in3 (600 cc)

No. Cylinders 2 4 6

No. Unloaders 0 1 1

Weight 84 lbs (38 kg) 108 lbs (49 kg) 137 lbs (62 kg)

Oil Charge 4.0 pints (1.9 L) 5.5 pints (2.6 L) 6.75 pints (3.2)

APPROVED COMPRESSOR OIL

Refrigerant 05G/05K

Mobile Arctic EAL 68

R-404A
Castrol Icematic SW68C

2.6.2.1 High Pressure Switches 2.6.3 Refrigeration System Data

HP1: 2.6.3.1 Defrost Timer
Opens on a pressure rise at:
465 ± 10 psig (32.7 ± 0.7 kg/cm2) 1-1/2, 3, 6, or 12 hours

Closes on a pressure fall at: 2.6.3.2 Defrost Thermostat

350 ± 10 psig (24.6 ± 0.7 kg/cm2)
Opens at: 47° ± 5°F (8° ± 3°C)
HP2 (860 Only):
Closes at: 37° ± 5°F (3° ± 3°C)
Closes on a pressure rise at:
440 ± 10 psig (29.9 ± 0.7 kg/cm2) 2.6.3.3 Defrost Air Switch Setting
Opens on a pressure fall at: Initiates at: 1.00 ± .07 inch (25.4 ± 1.8 mm) wg
367 ± 12 psig (25 ± 0.8 kg/cm2)
2.6.3.4 Refrigerant Charge
2.6.2.2 Compressor Discharge Temperature Sen-
Refer to Table 2–1
sor (CDT)
This is a thermistor type sensor located (when 2.6.3.5 Compressor Pressure Regulating Valve
installed) on the compressor discharge cover. (CPR)

Unit shuts down: CPR Setting CPR Setting

MODEL
• If ambient is less than 120°F (50°C) psig bar
AND
Temperature exceeds 310°F (154°C) for 3 min SUPRA 560 34 ± 1 2.3 ± 0.07
• If ambient is greater than 120°F (50°C) SUPRA 660 28 ± 1 1.91 ± 0.07
AND
Temperature exceeds 340°F (171°C) for 3 min SUPRA 760 32 ± 1 2.18 ± 0.07

• Immediately shuts down in all ambients SUPRA 860 34 ± 1 2.3 ± 0.07

If temperature exceeds 350°F (177°C)
SUPRA 960 29 ± 1 1.97 ± 0.07

2.6.3.6 Thermal Expansion Valve Superheat

Setting at 0°F (-17.8°C) box temperature:
8-10°F (-13.3 to -12.2°C)

62-11675 2-16
2.6.4 Electrical Data

2.6.4.1 Evaporator Fan Motors

Bearing Lubrication: Factory lubricated, additional grease not required.

Horsepower Operating Current Speed Voltage

0.15hp (112W) 9-10 amps 3000 to 3300 rpm 12 vdc

2.6.4.2 Standby Motors

Bearing Lubrication: Factory lubricated additional grease not required
Rotation Speed: 1760 rpm@ 60Hz/1500 rpm@ 50Hz

Voltage Power
Connection Type Full Load Amps
3ph, 60 Hz HP
SUPRA 560
230  20
5.9
460 Y 14
SUPRA 660/760
230  23
7.6
460 Y 13
SUPRA 860
230  19.6
8.3
460 Y 9.8
SUPRA 960
230  32
14.8
460 Y 23

2.6.4.3 Alternator: 70 amps

2.6.4.4 Standby Motor Overload

SETTING
MODEL
230V, 3 phase, 60 Hz 460V, 3 phase, 60 Hz

560 16 AMPS -

660/760 20 AMPS 10 AMPS

860 21 AMPS 11 AMPS

960 35 AMPS 23 AMPS

2-17 62-11675
2.6.4.5 Solenoids

Description Amperage Resistance  Voltage

HGS1 1.25 9.6 12 vdc

HGS2 1.16 10 12 vdc

Speed/Run/Damper 4.4 2.7 12 vdc

Unloader 1.3 9.6 12 vdc

2.6.5 Torque Values

Assembly ft-lb Nm

Power Tray to Frame 40 54.2

Standby Motor to Power Tray 22-28 30-44

Engine to Power Tray 50 67.8

Compressor to Power Tray 45-55 61-75

Standby Motor Pulley 36.8 50

Engine Pulley 22 29.8

Compressor Pulley 22 29.8

Evaporator Fan Motor 6-7 9.5

Evaporator Fan Grille 7 9.5

Condenser Coil to Chassis 7 9.5

Tensioner to Power Tray 22 29.8

Engine Support 40 54.2

Run & Speed Solenoids 7 9.5

Condenser Fan Blade 18 24.4

Engine Clutch 22 29

Suction Service Valve 22-25 30-34

62-11675 2-18
2.7 Safety Devices
System components are protected from damage caused by unsafe operating conditions by automatically shutting
down the unit when such conditions occur. This is accomplished by the safety devices listed in Table 2–11.

Table 2–11 Safety Devices - Microprocessor Controller

Unsafe Condition Safety Device Device Setting

1. Low engine lubricating oil Oil pressure safety switch Opens below 18 ± 3 psig
pressure (OP) automatic reset (1.2 ± 0.2 bar)

2. High engine coolant temperature Water temperature sensor Opens above 230 ± 5°F
(microprocessor) (110 ± 3°C)

3. Excessive current draw by glow Fuse (F1) Opens at 80 amps

plug circuit, control circuit or
starter solenoid (SS)

4. Excessive current draw by run Fuse (F2) Opens at 5 amps

control relay.

5. Excessive current draw by run Fuse (F3) Opens at 15 amps

relay

6. Excessive current draw heat Fuse (F4) Opens at 5 amps

relay

7. Excessive current draw by speed Fuse (F5) Opens at 10 amps

relay

8. Excessive current draw by Fuse (F6) (860 and 960 Only) Opens at 5 amps
unloader

9. Excessive current draw by Fuse (F7) (960 Only) Opens at 15 amps

defrost damper relay

10. Excessive current draw by Fuse (F8, F9, F10) Opens at 30 amps
evaporator fan motors

11. Excessive current draw by fuel Fuse (F11) Opens at 5 amps

pump

12. Excessive compressor discharge High pressure cutout switch Refer to Section 2.6.2
pressure (HP1) automatic reset

13. Excessive compressor discharge Compressor discharge Shuts unit down above 310°F (154°C)
temperature temperature sensor (CDT) for 3 minutes or 350°F (177°C)

14. Excessive current draw by fuel Fuse (F12) Opens at 25 amps

heater circuit (option)

2-19 62-11675
2.8 Refrigerant Circuit The liquid then flows through the liquid side of the heat
2.8.1 Cooling (See Figure 2.12) exchanger, where it is further reduced in temperature
by giving off some of its heat to the suction gas.
When cooling, the unit operates as a vapor compres-
The liquid then passes through the check valve and on
sion refrigeration system. The main components of the
to an externally equalized thermostatic expansion
system are the compressor, hot gas 3-way valve, con-
valve.
denser, thermostatic expansion valve and evaporator.
The refrigerant pressure drop caused by the expansion
The compressor raises the pressure and temperature
valve is accompanied by a drop in temperature so the
of the vapor, then forces it through the hot gas 3-way
low pressure, low temperature fluid that flows into the
valve (HGS1), then into the condenser tubes. The con-
evaporator tubes is colder than the air that is circulated
denser fan circulates surrounding air over the outside
over the tubes by the evaporator fans. The evaporator
of the condenser tubes. The tubes have fins designed
tubes have aluminum fins to increase heat transfer;
to improve the transfer of heat from the vapor to the air.
therefore heat is removed from the air circulated over
This removal of heat causes the refrigerant to liquefy;
the evaporator. This cold air is circulated throughout
thus liquid refrigerant leaves the condenser and,
the refrigerated compartment to maintain the cargo at
except for the 960, through a check valve to the
the desired temperature. The transfer of heat from the
receiver.
air to the low temperature liquid causes the refrigerant
The receiver stores the additional charge necessary for to vaporize.
low ambient operation and for the heating and defrost
This low temperature, low pressure vapor passes
modes. The receiver is equipped with a relief valve
through the suction side of the heat exchanger where it
which opens if the refrigerant pressure is abnormally
absorbs more heat from the high pressure/high tem-
high and releases the refrigerant charge.
perature liquid and then returns to the accumulator.
The liquid leaves the receiver and flows through the
The vapor is drawn out of the accumulator through a
receiver service valve to the subcooler. The subcooler
pickup tube which is equipped with a metering orifice.
occupies a portion of the main condensing coil surface
This orifice prevents the accumulation of oil in the
and gives off further heat to the passing air.
accumulator tank. The metering orifice is calibrated to
The liquid then flows through a filter-drier where an control the rate of oil flowing back to the compressor.
absorbent keeps the refrigerant clean and dry.
The vapor then enters the compressor pressure regu-
lating valve (CPR) which regulates refrigerant pressure
entering the compressor, where the cycle starts over.

62-11675 2-20
 Figure 2.12 Refrigeration Circuit - Cooling

FILTER DRIER
EVAPORATOR

TXV TXV HOT GAS RECEIVER SERVICE

BULB
BYPASS VALVE
SOLENOID
VALVE
CHECK (HGS2)**
VALVE** INLET
DRAIN PAN HEATER CHECK
VALVE
RECEIVER

HEAT HOT GAS 3ïWAY

EXCHANGER VALVE (HGS1)

SUBCOOLER
COMPRESSOR
PRESSURE DISCHARGE
REGULATOR SERVICE
VALVE VALVE HP2
*

SPT
HP1 CONDENSER

METERING * 860 ONLY

SUCTION
ORIFICE **560/660/760/860 ONLY
SERVICE
ACCUMULATOR VALVE Discharge
Liquid
Suction
COMPRESSOR Inactive

2.8.2 Heat And Defrost (See Figure 2.13) The hot gas bypass solenoid valve (HGS2) (not on
960) also opens during heating to provide additional
When refrigerant vapor is compressed to a high pres-
refrigerant to the compressor from the receiver. This
sure and temperature in a reciprocating compressor,
increases the amount of refrigerant in circulation,
the mechanical energy necessary to operate the com-
increasing heating capacity.
pressor is transferred to the vapor as it is being com-
pressed. This energy is referred to as the “heat of The main difference between heating and defrosting is
compression” and is used as the source of heat during that, when in heating the evaporator fans continue to
the heating cycle. run, blowing the air over the heated coils to heat the
product. When defrosting, the evaporator fans stop,
When the controller calls for heating or defrost, the hot
allowing the heated vapor to defrost any ice build up
gas 3-way valve (HGS1) solenoid energizes, closing
there may be.
the port to the condenser and opening a port which
allows heated vapor to flow through the drain pan The hot gas bypass line draws refrigerant from the
heater tube to the evaporator coil. receiver and injects it through a metered valve into the
suction line between the compressor pressure regula-
tor valve and the compressor. This will raise the dis-
charge pressure and temperature.

2-21 62-11675
 Figure 2.13 Refrigeration Circuit - Heat and Defrost

EVAPORATOR FILTER DRIER

TXV TXV
HOT GAS RECEIVER SERVICE
BULB BYPASS VALVE
SOLENOID
VALVE
CHECK (HGS2)**
VALVE** INLET
DRAIN PAN HEATER
CHECK
VALVE
RECEIVER

HOT GAS 3ïWAY

HEAT VALVE (HGS1)
EXCHANGER
SUBCOOLER

COMPRESSOR
PRESSURE DISCHARGE
REGULATOR SERVICE
HP2
VALVE VALVE
*

SPT
HP1 CONDENSER

METERING * 860 ONLY

ORIFICE SUCTION
SERVICE **560/660/760/860 ONLY
ACCUMULATOR VALVE Discharge
Liquid
COMPRESSOR Suction
Inactive

62-11675 2-22
 SECTION 3
Operation
3.1 Microprocessor Controller The Carrier Transicold Microprocessor System incor-
porates the following features:
3.1.1 Introduction
• Control supply or return air temperature to tight
limits by providing refrigeration control, heat and
! CAUTION defrost to ensure conditioned air delivery to the
load.
Under no circumstances should anyone
attempt to repair the Logic or Display • Default independent readouts of set point (at the
Boards. Should a problem develop with left of the display) and actual supply or return air
these components, contact your nearest temperature (at the right).
Carrier Transicold dealer for replace- • Digital readout of unit data points such as pres-
ment. sures, temperatures and other microprocessor
inputs.
The Microprocessor consists of the microprocessor
module, relay/fuse board (Figure 2.4), Cab Command • Digital readout of selectable operating parame-
(Figure 3.1) and interconnecting wiring. ters (Function Codes) and the ability to change
those set tings.
• The Microprocessor module includes the tem-
perature control software and necessary input/ • Digital display of Alarm Indications.
output circuitry to interface with the unit controls.
• A self-test check on program memory and data
• The Relay Board contains replaceable relays memory at start-up.
and fuses.
• A Pre-Trip checkout of refrigeration unit operation.
• The Cab Command is remote mounted in the
• An optional RS232 communication port to com-
truck. The Cab Command includes the LCD dis-
municate unit operating data to a mobile satellite
play and keypad. The keypad and display serve
transmitter. This information will then be relayed
to provide user access and readouts of micro-
back to the office via a modem to a computer.
processor information. The information is
accessed by keypad selections and viewed on There are presently three protocols sup-
the display. ported. The protocol for the QualComm
transmitter, the protocol for the HUGHES
transmitter, and the Carrier Communication
Protocol. The microprocessor will transmit a
HUGHES protocol packet every hour.
Transmission with the Carrier or QualComm
protocol is by request.

3-1 62-11675
 Figure 3.1 Cab Command

12 13 14 15 16 17 19 20
18

1
ALARM/FAULT

-20 35 F i 2
UNIT DATA

SETPOINT BOX TEMPERATURE

ENTER
3
FUNCTION
AUTO START/STOP

PRETRIP 4
O
O I

ROAD CITY MAN BUZZER OFF STANDBY

SPEED DEFROST

11 10 9 8 7 6 5

1. Unit Data Key 11. I/O Switch

2. Auto Start/Stop - Continuous Run Key 12. Cool Mode
3. Pretrip Key 13. Heat Mode
4. Stand-by Key 14. Defrost Mode
5. Buzzer Off Key 15. Road Mode
6. Enter Key 16. Auto Start/Stop Mode
7. Manual Defrost Key 17. Stand-by Mode
8. City Speed Key 18. City Speed Mode
9. Road Key 19. Out-of-range
10. Function Key 20. Fault Light

3.2 Microprocessor Configuration

The microprocessor is configured in accordance with Arrow Keys
the equipment supplied on an individual unit and the
The up and down ARROW
requirements of the original purchase order. The con-
keys are used to modify
figurations do not require change unless the unit has
(increment or decrement) the
an equipment change or a change is required by the
displayed data. If the unit is in
owner. Although the configurations may not be modi-
the default display these keys are pressed to change
fied using the keypad, operational differences will be
the setpoint selection.
noted throughout the following descriptions and operat-
ing procedures. See Table 6–4 for list of microproces- Enter Key
sor configuration codes.
The ENTER key is used to accept a
Some microprocessor settings such as setpoint and change in function codes or a change in
functional parameters may be changed at the keypad setpoint.
and are described in the following sections.

3.3 Description of Microprocessor Components Manual Defrost Key

3.3.1 Keypad The MANUAL DEFROST key is used to

initiate a defrost cycle. If the predeter-
The keypad (Figure 3.1) has 12 keys which allow the mined conditions for defrost are not met,
operator to initiate various functions, display operating the unit will not enter defrost and the dis-
data and change operating parameters.
play will return to the default screen.

62-11675 3-2
Pretrip Check Key Buzzer Off Key
The PRETRIP key is used to initiate a The BUZZER OFF key will disable the cab
pretrip test cycle. If the predetermined command buzzer. When not disabled by
conditions for pretrip are not met, the unit use of this key, the buzzer is activated
will not enter pretrip and the display will whenever the alarm/fault indicator is illu-
return to the default screen. minated. The buzzer off indicator on the
display will illuminate when the buzzer is
Auto Start/Stop - Auto Start/Continuous Run Key disabled.
The AUTO START/STOP key is used to
Road Key
change the operating mode from Continu-
ous Run to Auto Start/Stop. Each push of The ROAD key selects the diesel engine
the key will alternate the operating modes. operating mode. The microprocessor re-
The microprocessor retains the last en- tains the last entered setpoint in memory
tered setpoint in memory even if the unit is even if the unit is shut down or a power
shut down or a power failure occurs. The failure occurs.
Auto Start/Stop indicator on the display will
illuminate when Auto Stop/Start is en- NOTE
abled. If the indicator is not illuminated, the When functional parameter “FN10” is set for
unit is in the Continuous Run Mode. time start, the unit optional auto diesel
restart is active and the Road key will be
NOTE flashing.
When configuration CNF11 is ON and set
point is 32 to 42°F (0 to 5.5°C) the unit is Stand-by Key
locked into continuous run. The AUTO The STAND-BY key selects the electric
START/STOP key is disabled. motor operating mode. The microproces-
sor retains the last entered setpoint in
Function Change Key
memory even if the unit is shut down or a
The FUNCTION CHANGE key is used to power failure occurs. NO POWER will be
display the function codes. Each time this displayed, if unit is switched to standby
key is pressed the display will advance to and power is not available.
the next code. This key, in conjunction with
the ARROW and ENTER keys, will allow 3.3.2 Digital Display
the user to change the Function Parame-
The digital display (see Figure 3.1) has nine positions.
ters. See Section 3.4.9 for more detailed
The default display is setpoint on the left and actual
information. supply or return air temperature on the right. The read-
Unit Data Key out may be set to read in Degrees F or Degrees C.

The UNIT DATA key is used to display the The display also has symbol -type indicators for the fol-
lowing modes: Cool, Heat, Defrost, Road (diesel) Opera-
i unit operating data. This key, in conjunc-
tion, Auto Start/Stop mode, Stand-By mode, City Speed
tion with the ARROW keys, will allow the
mode and Out-Of-Range operation. The indicator is illu-
user to display the unit's operating data
minated to indicate the mode or condition is active.
values (i.e, coolant temperature, battery
voltage, etc.) See Section 3.4.10 for On each power-up, the microprocessor will perform a
more detailed information. self test. Errors, if any, will be indicated on the display
as an EER.# where # is a number corresponding to the
City Speed Key number of the failed test.
The CITY SPEED key enables the city
speed mode of operation. In the city speed ERROR CAUSE
mode, the unit will operate in low speed.
Each push of the key toggles the operating ERR.1 Processor failure
mode to ROAD SPEED mode. The micro- ERR.2 • Check chip installation or
processor retains the last entered setpoint ERR.3 Replace microprocessor.
in memory even if the unit is shut down or
a power failure occurs. The city speed indi- ERR.4 or Display board to logic board commu-
cator on the display will illuminate when the Display nication failure.
city speed mode is enabled. • This can be caused by a defec-
tive ribbon cable or ribbon
cable not plugged in properly.

3-3 62-11675
3.4 Operation 4. After operating unit 15 minutes or more:

3.4.1 Pre-Trip Inspection a. Check water temperature. Should be 160 to

175°F (72 to 80°C).
1. Pre-Trip Inspection - Before Starting engine
b. Check refrigerant level. (Refer to Section
check the following points:
6.10.4.)
a. Drain water and sediment from fuel tank sump. c. Check compressor oil level. (Refer to Section
Then fill tank with diesel fuel. 6.12.1.)
b. Drain water from fuel filter separator (if applicable). d. Put unit into manual defrost and monitor. Allow
unit to terminate defrost automatically.
c. Check radiator coolant level. Antifreeze should
be adjusted for climate conditions, minimum 50/ e. Change over to desired operating mode, enter
50 mixture, maximum 60/40 mixture. set point and change functional parameters as
required to match the requirements of the load.
d. Check condenser/radiator coil for cleanliness.
e. Check air cleaner and hoses. ! WARNING
f. Check Defrost Air Switch and hoses. Under no circumstances should ether or
g. Check engine oil level. any other starting aids be used to start
engine.
h. Check condition and tension of all belts.
3.4.2 Starting - Road Operation
i. Check all fan and idler bearings.
1. Place the I/O Switch in the I position.
j. Check door latches and hinges.
2. If the unit has been used previously in the
k. Check condition of condenser fan blades. standby mode, press the road operation button.
l. Check battery fluid level (if applicable). 3. Under normal circumstances this is all that is re
quired to start the unit. The unit will then perform
m. Check battery cables and terminals. a complete diagnostic check on the micropro-
n. Check evaporator coil for cleanliness. cessor controller, pre-heat for the required
amount of time based on the engine tempera-
o. Check evaporator fan. ture and start automatically.
p. Check air chute (if applicable). 4. Enter Set Point and change Functional Parame-
ters to match the requirements of the load.
q. Check bulkhead and return air screens (if appli-
cable). 3.4.3 Starting - Standby Motor Drive

r. Check defrost water drains.

s. Check glow plugs. ! WARNING
Make sure the power plug is clean and dry
2. Pre-Trip Inspection - Starting
before connecting to any power source.
a. Start the unit in continuous run. Refer to Section
3.4.2. Do not attempt to connect or remove
power plug or perform service and/or
3. Pre-Trip Inspection - After Starting engine check maintenance before ensuring the unit
the following points: RUN/STOP Switch is in the STOP position
and the I/O Switch is in the O position.
a. Check electric fuel pump.
1. Place the I/O (Cab Command) and unit RUN/
b. Check fuel lines and filters for leaks. STOP Switches in the ON position and press
c. Check oil lines and filters for leaks. the STAND BY key. The microprocessor will per-
form a self-test (all display messages will
d. Check coolant hoses for leaks. appear in display window). Then setpoint and
box temperature will be displayed.
e. Check exhaust system for leaks.
NO POWER will be displayed if unit is
f. Check condenser and evaporator fans for switched to STANDBY and power is not
proper air flow. available.
g. Initiate Pre-Trip and monitor all operating modes. 2. Enter Set Point and change Functional Parame-
Check unloader operation (860 and 960). ters to match the requirements of the load.

62-11675 3-4
3.4.4 Pre-Trip 3.4.6 Start/Stop Operation
Pre-Trip is a test sequence that the operator may initi- After start up, observe the AUTO START/STOP indica-
ate to check unit operation. During Pre-Trip, the micro- tor. If it is illuminated, the unit is in the Auto Start/Stop
processor operates the unit in various modes allowing mode. If not, press the Auto Start/Stop key to toggle the
evaluation of unit operation. If a failure occurs during unit into Auto Start/Stop mode.
Pre-Trip, the microprocessor will generate an alarm.
Automatic start/stop is provided to permit starting/
The following steps detail the sequence:
restarting of the diesel-driven compressor as required.
1. The unit is operated to bring box temperature This gives the microprocessor automatic control of
below 40°F (4.4°C). starting and stopping the diesel engine. The main func-
tion of automatic start-stop is to turn off the refrigeration
2. The operator presses the PRETRIP key. If the system near the setpoint to provide a fuel efficient tem-
defrost thermostat (DTT) is closed, the micro- perature control system and then restart the engine
processor will display PPPP and the test is when needed. Start-Stop operation is normally used for
started. If DTT is open, the test will end. frozen loads.
3. After 30 seconds in high speed cool, unit cycles Enter Set Point and change Functional Parameters to
to low speed loaded cool. match the requirements of the load.

4. After 30 seconds, unit cycles to low speed Whenever the unit starts in Auto Start-Stop, it will run
unloaded cool. until:
• It has run for the predetermined minimum run
5. After 30 seconds, unit cycles to low speed
time.
unloaded heat.
• The engine coolant temperature is above 122°F
6. After 30 seconds, unit cycles to low speed (50°C)
loaded heat.
• The box temperature is at setpoint.
7. After 30 seconds, unit cycles to high speed heat
and displays coolant temperature. The controller will not shut off the engine if the battery
voltage is not sufficient to restart it. Battery voltage
8. After 30 seconds, unit cycles to high speed cool above approximately 13.4 volts is required for shut-
and displays the defrost interval selection for 30 down. This varies depending on ambient. Look at bat-
seconds, then unit cycles to defrost if DTT is tery voltage in data list to find out whether shutdown
closed. voltage has been reached. If there is a + in front of the
number, the voltage is enough to shutdown and restart.
9. After standard defrost cycle, Pre-Trip is termi- If only the number appears, the voltage is still too low
nated and unit returns to normal operation. for shutdown.
3.4.5 Setpoint The controller will restart the engine if any of the follow-
ing criteria have been met:
NOTE
• Box temperature has changed by ± 11°F (±
If configuration CNF3 is ON maximum set
6.1°C) for setpoints in the perishable range and
point is increased to 90°F.
+11° F (+6.1°C) for setpoints in the frozen range
Setpoints of -22°F to +86°F (-30°C to +30°C) may be DURING minimum off time.
entered via the keypad. • Box temperature has moved away from setpoint
by ± 3.6°F (2.0°C) AFTER minimum off time for
With the default screen showing on the display, the up
setpoints in the perishable range or +0.5°F
or down ARROW key may be pressed to bring the set
(0.3°C) for setpoints in the frozen range.
point to the desired reading. The display will flash to
indicate that the reading being displayed is a non- • The battery voltage drops below 12.2 VDC Refer
entered value. to Table 32 for unit data).
Depress the ENTER key to activate the new setting. • The engine coolant temperature drops below
34°F (1°C).
If the ENTER key is not pressed within five seconds
after the last key stroke, the display will revert to the NOTE
previous active setting. The microprocessor retains the When configuration CNF11 is ON and set
last entered setpoint in memory even if the unit is shut point is 32 to 42°F (0 to 5.5°C) the unit is
down or a power failure occurs. locked into continuous run. The AUTO
START/STOP key is disabled.

3-5 62-11675
 held for one second, the list will scroll at a rate of one
NOTE
item every 0.5 seconds. Once the end of the list is
Auto Start-Stop operation may be tied to the reached the list will scroll back to the first entry.
setpoint ranges for frozen and perishable
loads and the AUTO START/STOP key may With a function parameter displayed, the data choice
be locked out. can be changed by pressing ENTER then pressing
either the up or down ARROW keys. The displayed
3.4.7 Continuous Run Operation choice will then flash to indicate that the choice has not
been entered. Depress the ENTER key to activate the
After start up, observe the AUTO START/STOP indica-
new choice. The display will stop flashing to indicate
tor. If it is illuminated, the unit is in the Auto Start/Stop
that the choice has been entered.
mode. If Continuous Run operation (unit will operate
continuously after starting) is desired, press the Auto If the new choice is not entered in 5 seconds, the dis-
Start/Stop key to change the operation to Continuous play will revert back to the last entered choice. All func-
Run. tion parameters are retained in memory. Descriptions
of the function parameters and operator choices are
In the Continuous Run mode, the diesel engine will run
provided in the following paragraphs. A function param-
continuously providing constant air flow and tempera-
eter listing is also provided in Table 31.
ture control to the product. Continuous Run operation
is normally used for perishable loads. 3.4.9.1 Defrost Interval
Continuous operation may be tied to the setpoint The English display for Defrost Interval is DEFR the
ranges for frozen and perishable loads and the AUTO code display is FN0. The choices are displayed with
START/STOP key may be locked out. one decimal place and then the capital letter H for
The unit will remain in low speed for 10 minutes after hours (i.e., DEFR 12.0H). The defrost choices are 1.5,
engine start-up when the Continuous Run setpoint is 3, 6 or 12 hours.
below 10°F (-12°C).
3.4.9.2 Speed Control
Enter Set Point and change Functional Parameters to
match the requirements of the load. The Speed Control parameter overrides the normal
microprocessor speed control solenoid operation.
3.4.8 Defrost Cycle Parameter English displays are CITY SPD or HIGH
SPD. The code displays are FN1 ON or FN1 OFF. With
Defrost is an independent cycle overriding cooling and CITY SPD or FN1 ON displayed the unit is locked into
heating functions to de-ice the evaporator as required. low speed. With HIGH SPD or FN1 OFF displayed,
For manual initiation, check that the box temperature is speed is under normal microprocessor control.
40 ° F (4 .4°C ) o r low er a nd pr es s th e M ANUAL
DEFROST key. 3.4.9.3 Minimum Off-Time

The microprocessor will displays DF on the right of the The auto start mode Minimum Off-Time parameter
display during defrost mode. The left display will con- English display is OFF T the code display is FN2. The
tinue to display the setpoint. Defrost may be terminated choice for the off-time is displayed with two digits and
in any of three ways; timer initiation, air switch initiation then the capital letter M for minutes (i.e. OFF T 20M or
and manually. FN2 20M). The off-time choices are 10, 20, 30, 45 or
90 minutes.
Refer to Section 4.1.6 for a more detailed description
of the defrost cycle. 3.4.9.4 Minimum On-Time

3.4.9 Functional Parameters The auto start mode Minimum On-Time parameter
English display is ON T. The code display is FN3. The
If configuration CNF11 is ON functional parameters are choice for the on-time is displayed with two digits and
locked out and the ability to change functional parame- then the capital letter M for minutes (i.e. ON T4 M).The
ters from keypad is disabled. on-time choices are 1 or 4 minutes.
The Function Parameters control selected operating
3.4.9.5 Controlling Probe
features of the unit. These parameters can be dis-
played by pressing the FUNCTION CHANGE key. The Controlling Probe parameter English displays are
When multiple choices are available, the display will REM PROBE or SUP PROBE. The code displays are
show the function description on the left side with the FN4 A or FN4 B. With REM PROBE or FN4 A dis-
corresponding function choice on the right side. The list played, the microprocessor is set for operation with a
can be scrolled through by pressing the FUNCTION single probe sensing return air temperature. With SUP
CHANGE key or by using the ARROW keys. With each PROBE or FN4 B displayed, the microprocessor is set
FUNCTION CHANGE key push, the list is advanced for dual probe (supply air or return air) control.
one. If the FUNCTION CHANGE key is pressed and

62-11675 3-6
3.4.9.6 Standard Units Select OFF and an out of tolerance condition exists,
The Standard Unit Select parameter allows selection of the unit will continue to operate but generate
English or metric data display. The English display is Alarm 20 (RAS OUT).
DEGREES F or C. The code display is FN5. The The English display for Out-Of-Range Temperature Tol-
choices are°C and °F. This parameter will also convert erance is T RANGE. The code display is FN11. The
pressure readings to psig or bars. choices are A, B or C. A = 3.6°F (2°C), B = 5.4°F (3°C)
and C = 7.2°F (4°C).
3.4.9.7 Maximum Off Time
The auto start mode Maximum Off Time English dis- When the out-of-range temperature is configured ON,
play is TIME START or TEMP START the code display the microprocessor indicates out-of-range when the
is FN6 ON or FN6 OFF. With TIME START or FN6 ON temperature has been within the tolerance band at
displayed the engine will be started 30 minutes after least once, and then goes outside the tolerance band
shutdown. With TEMP START or FN6 OFF displayed for 45 minutes. Also, the unit will shut down.
the engine will be under normal microprocessor tem- When the out-of-range temperature is configured OFF,
perature control. the microprocessor indicates out-of-range when the
temperature has been within the tolerance band at
3.4.9.8 Diesel Backup Feature least once, and then goes outside the tolerance band
If the unit is in standby mode and AC power is lost for for 15 minutes. Also, the unit will continue to operate.
five minutes or more, the diesel engine will start and
For set points at or below +10°F (-12.2°C) frozen range
run until AC power is restored and applied for five min-
the unit is only considered out-of-range for tempera-
utes. The ROAD icon will blink once every second
tures above set point.
while the PLUG icon will stay on constantly to indicate
that this feature is active. 3.4.9.14 Code vs. English Messages
When the five minute shutdown timer expires and AC The function descriptions, unit status and alarms can
power is present, the unit will shut down the diesel be displayed in English or codes through this function
engine and restart the standby motor. If AC power is selection. The choices are displayed as ENGLISH or
NOT present, the diesel engine will operate. CODES. Refer to Table 3–1 for a listing of the display
If the unit is set to TEMP START the standby diesel readings when the English or Code choice is activated.
back up feature will be turned off and the unit will oper-
3.4.9.15 Manual Glow Override
ate in normal standby mode.
The auto start glow time can be manually overridden
3.4.9.9 MOP STD - Future Expansion through this function. The choices are displayed as
Used to add or subtract 5psig (0.34 Bar) to unloader NORM GLOW or ADD GLOW. If the ADD GLOW
equations. English display is MOP STD. The code dis- selection is entered, the control will add additional glow
play is FN7. time.

3.4.9.10 Compartment 2 Setpoint - N/A 3.4.9.16 Alarm Reset

Alarms can be reset through this function. The mes-
English display is 2SET. The code display is FN8.
sages are displayed as ALARM RST or ALARM CLR. If
3.4.9.11 Compartment 3 Setpoint - N/A the ALARM RST is displayed then there is at least one
alarm present. Pressing the ENTER key will clear all
English display is 3SET. The code display is FN9. the alarms. If ALARM CLR is displayed then there are
no alarms present.
3.4.9.12 Auto/Manual Start Operation
The English displays for Auto/Manual Start Operation 3.4.10 Unit Data
are AUTO OP and MAN OP. The code displays are The UNIT DATA key can be used to display the micro-
FN10 ON and FN10 OFF. With AUTO OP or FN10 ON processor input data values. The display will show the
displayed the unit will start automatically. With MAN OP description of the input on the left side with the actual
or FN10 OFF displayed the unit must be in Auto Start/ data on the right side. The unit data list can be scrolled
Stop mode to start. through by pressing the UNIT DATA key. With each suc-
cessive key push, the list is advanced one. If the UNIT
3.4.9.13 Out-of-Range Tolerance DATA, or an ARROW key is held for one second, the list
will scroll at a rate of one item every 0.5 seconds. Once
NOTE
the end of the list is reached, the list will scroll back to
If configuration CNF9 is ON the unit will shut the first entry. The display will revert back to the default
down if an out of tolerance condition exists display if no keys are pressed for 5 seconds.
for over 45 minutes. If configuration CNF9 is

3-7 62-11675
If the ENTER key is pressed, the display time will be increased to 30 seconds. A description of the unit data read-
ings is provided in the following paragraphs. A Unit Data listing is provided in Table 3–2.

Table 3–1 Functional Parameters

CODE ENGLISH DATA

FN0 DEFR Defrost Interval

FN1 ON CITY SPD Low Speed

FN1 OFF HIGH High Speed

SPD

FN2 OFF T Minimum Off-time

FN3 ON T On-time

FN4 a REM Controlling Probe - Return

PROBE Air

FN4 b SUP Controlling Probe - Supply

PROBE Air

FN5 Degrees Temperature Unit °C or °F

F or C

FN6 ON TIME Maximum Off-time 30 Min.

STRT

FN6 OFF TEMP Temperature Based

STRT Restarting

FN7 MOP STD Unloader control

FN8 2SET N/A

FN9 3SET N/A

FN10 ON AUTO OP Auto Start Operation

FN10 MAN OP Manual Start Operation

OFF Do Not Use

FN11 T RANGE Out-of-Range Tolerance

Code vs English = Code or English display format

Manual Glow Override = Normal or Add 30sec

Alarm RST = Alarm Reset Required

Alarm CLR = No Alarm Active

62-11675 3-8
 Table 3–2 Unit Data Codes 185.0F) while the metric are designated by a C (i.e, WT
85.0C or CD3 85.0C). The display range is 10°F to
CODE ENGLISH DATA 266°F (-12°C to 130°C).
CD1 SUCT Suction Pressure 3.4.10.4 Return Air Temperature
CD2 ENG Engine Hours The English display for Return Air Temperature is RAS,
the code display is CD4. The English units are desig-
CD3 WT Engine Temperature nated by an F following the reading (i.e, RAS 35.0F or
CD4 RAS Return Air Temperature CD4 35.0F) while the metric are designated by a C (i.e,
RAS 1.7C or CD4 1.7C). The display range is 10°F to
*CD5 SAS Supply Air Temperature 266°F (-12°C to 130°C).

*CD6 REM Remote Air Temperature 3.4.10.5 Supply Air Temperature

CD7 ATS Ambient Temperature The English display for Supply Air Temperature is SAS,
the code display is CD5. The English units are desig-
CD8 EVP Future Expansion nated by an F following the reading (i.e, SAS 35.0F or
CD5 35.0F) while the metric are designated by a C (i.e,
CD9 CDT Discharge Temperature
SAS 1.7C or CD5 1.7C). The display range is -36°F to
CD10 BATT Battery Voltage 158°F (-38°C to 70°C). The data will be displayed only
if the SUP PROBE is selected in the controlling probe
CD11 SBY Standby Hours functional parameter.
CD12 MOD V Future Expansion 3.4.10.6 Remote Air Temperature
CD13 REV Software Revision The English display for Remote Air Temperature is
REM, the code display is CD6. The English units are
CD14 SERL Serial Number Low designated by an F following the reading (i.e, REM
CD15 SERU Serial Number Upper 35.0F or CD6 35.0F) while the metric are designated
by a C (i.e, REM 1.7C or CD6 1.7C). The display range
CD16 2RA N/A is -36°F to 158°F (-38°C to 70°C). The data will be dis-
played only if the REM PROBE is selected in the con-
CD17 3RA N/A trolling probe functional parameter.
CD18 MHR1 Maintenance Hour Meter 1
3.4.10.7 Ambient Temperature
CD19 MHR2 Maintenance Hour Meter 2 The English display for Ambient Air Temperature is
ATS, the code display is CD7. The English units are
CD20 SON Switch On Hour Meter
designated by an F following the reading (i.e, ATS
*Codes 5 & 6 are variable. SAS is displayed when 85.0F or CD7 85.0F) while the metric are designated
the SUP Probe Function is selected. REM is dis- by a C (i.e, ATS 29.4C or CD7 29.4C). The display
played when the REM Probe Function is selected. range is-36°F to 158°F (-38°C to 70°C).

3.4.10.8 EVP - Future Expansion

3.4.10.1 Suction Pressure
This unit data is not used at this time. The English dis-
The English display for Suction Pressure is SUCT, the
play is EVP. The code display is CD8.
code display is CD1. The English units are designated
by a P (psig) following the reading while the metric are 3.4.10.9 Compressor Discharge Temperature
designated by a B (bar). English readings below 0 are
in inches of mercury. The display range is -20 hg to 420 The English display for Compressor Discharge Tem-
psig (-0.7 to 29.4 bar). perature is CDT, the code display is CD9. The English
units are designated by an F following the reading (i.e,
3.4.10.2 Engine Hours CDT 185.0F or CD9 185.0F) while the metric are desig-
nated by a C (i.e, CDT 85.0C or CD9 85.0C). The dis-
The English display for Engine Hours is ENG, the code
play range is -40°F to 392°F (-40°C to 200°C).
display is CD2. The data is displayed with units desig-
nator H (i.e, ENG 5040H or CD2 5040H). The display 3.4.10.10 Battery Voltage
range is 0 to 99999.
The English display for Battery Voltage is BATT, the
3.4.10.3 Engine Temperature code display is CD10. The reading is displayed the
capital letter V for volts (i.e, BATT 12.2V or CD10
The English display for Engine Temperature is WT, the
12.2V). The voltage reading is displayed with a + plus
code display is CD3. The English units are designated
sign if the battery status is acceptable for shut down
by an F following the reading (i.e, WT 185.0F or CD3
and auto start mode.

3-9 62-11675
3.4.10.11 Standby Hours 3.4.10.17 Compartment 3 Air Temperature
The English display for Standby Motor Hours is SBY, The English display for the Third Compartment Air
the code display is CD11. The data is displayed with Temperature is 3RA, the code display is CD17.
units designator H (i.e, SBY 5040H OR CD11 5040H).
The display range is 0 to 99999. 3.4.10.18 Maintenance Hour Meter 1
The English display for the Maintenance Hour Meter 1
3.4.10.12 MOD V - Future Expansion is MHR 1, the code display is CD18. The data is dis-
This unit data is not used at this time. The English dis- played with units designator H (i.e, MHR 1 5040H OR
play is MOD V. The code display is CD12. CD18 5040H). The display range is 0 to 99999. The
maintenance hour meter is compared to one of the
3.4.10.13 Software Revision hour meters (diesel, standby, or switch on) determined
The English display for the Eeprom Software Revision by its mode. If the hour meter is greater than the main-
is REV. The code display is CD13. The actual Eeprom tenance hour meter an alarm will be generated.
software revision number is displayed on the right. If
the ENTER key is depressed for three seconds while 3.4.10.19 Maintenance Hour Meter 2
the Eeprom Software Revision is displayed, the display The English display for the Maintenance Hour Meter 2
will revert to the Board Mounted Software display. The is MHR 2, the code display is CD19. The data is dis-
English display will change to REV U2 on the left and played with units designator H (i.e, MHR 2 5040H OR
the actual board mounted software revision number will CD19 5040H). The display range is 0 to 99999. The
be displayed on the right. maintenance hour meter is compared to one of the
hour meters (diesel, standby, or switch on) determined
3.4.10.14 Serial Number Low by its mode. If the hour meter is greater than the main-
The English display for the Low Serial Number of the tenance hour meter an alarm will be generated.
Eeprom is SERL The code display is CD14. The lower
3 digits of the Eeprom serial number will be displayed 3.4.10.20 Switch On Hour Meter
on the left. (i.e, SERL 504 or CD14 504). The Switch On Hour Meter displays the total operating
hours (engine & standby) on the unit. The English dis-
3.4.10.15 Serial Number Upper play for the Switch On Hour Meter is SON, the code
The English display for the Upper Serial Number of the display is CD20. The data is displayed with units desig-
Eeprom is SERU The code display is CD15. The upper nator H (i.e, SON 5040H OR CD20 5040H). The dis-
3 digits of the Eeprom serial number will be displayed play range is 0 to 99999.
on the left. (i.e, SERH 001 or CD14 001).

3.4.10.16 Compartment 2 Air Temperature - N/A 3.4.11 Stopping Instructions

The English display for the Second Compartment Air O To stop the unit, from any operating mode,
Temperature is 2RA, the code display is CD16. O I place the I/O (Cab Command) or RUN/
STOP Switch in the OFF position.

62-11675 3-10
 SECTION 4
Control Logic and Temperature Control
4.1 Modes of Operation The microprocessor will continue to monitor changes in
temperature and switch the unit between high speed
The operational software responds to various inputs.
cool, low speed cool, low speed heat and high speed
These inputs come from the temperature and pressure
heat as required to maintain desired temperature. If
sensors, the temperature set point, the settings of the AUTO START/STOP is activated, the microprocessor
configuration variables and the function code assign- will add a null mode at or near setpoint and shut down
ments. The action taken by the operational software the unit when conditions allow. See Figure 4.5.
will change if any one of the inputs changes. Overall
interaction of the inputs is described as a mode of The microprocessor will monitor temperature while in
operation. The modes of operation include cooling, the null mode and restart the unit following the same
heat and defrost. Refer to Section 2.8 for a description procedures used to prevent overshoot when switching
of the refrigerant circuit. to other modes. The length of time the unit will remain
in the null mode is also dependent on Function Code
If the unit is operating in AUTO START/STOP, a fourth settings. Function Code FN2 will control the minimum
mode is added. This is the null mode. In the null mode, the off time after shut down, Code FN3 will control the min-
unit shuts down until further cooling or heating is required. imum on time before the null mode can be entered
The cooling mode is further divided into the perishable again, Code FN6 will control the maximum off time or
(chill) range operation and frozen range operation. At allow temperature based restarting. Refer to Section
3.4.9 for Functional Parameter descriptions.
setpoints above 10°F (-12°C) the unit will operate in the
perishable range. In perishable range, all modes of 4.1.2 Start-up & Pull Down - Standby Operation
operation are available to the microprocessor. At a set-
point of 10°F (-12°C) or below, the unit will operate in Operation in standby follows the same sequence as
the frozen range. In frozen range, heat is locked out operation on the engine except the standby motor
and only the cool and defrost modes are available to operates at a single speed. The microprocessor will
the microprocessor. Heat lockout can be overridden by monitor changes in temperature and switch the unit
setting CNF4 to ON. See Table 6–4. between the cool mode, null mode and heat mode. The
microprocessor will add the null mode at or near set-
4.1.1 Start-up & Pull Down - Engine Operation point and de-energize the motor when conditions allow.
At startup, the unit operates in high speed cool with 4.1.3 Null Mode Overrides
evaporator fans shut off (unloaders are energized for 860
and 960 units) for a period of 3 minutes (or 92 seconds if When in the null mode two conditions will override nor-
engine coolant temperatures are less than 19°F or com- mal microprocessor off time and/or temperature con-
pressor discharge temperatures are higher than 176°F). trol. If the unit is in the Engine Drive or Standby mode
and battery voltage falls below 12.2 volts, the engine or
The microprocessor then checks to see if City Speed is motor will be restarted to allow the alternator to
activated. If City Speed is activated, high speed is recharge the battery. If the unit is in the Engine Drive
locked out. The unit will be brought to low speed and mode and the engine coolant temperature drops below
the following operations will all take place in low speed. 34°F (1°C) the engine will be restarted.
Also, the unit is locked in cooling during the oil pres-
sure delay. If heating is required, the unit will switch to 4.1.4 Dual Probe Operation
heating after the oil pressure delay time has expired. The microprocessor is fitted with a connection for a sec-
If City Speed is not activated, the unit will remain in ond thermistor. This thermistor is installed in the supply
high speed heat or cool for the selected minimum run air stream and activated using Function Code FN4. With
time (Function Code FN3). Function Code FN4 set to FN4 ON or REM PROBE the
microprocessor is set for dual probe control.
As box temperature is reduced, the microprocessor will
switch to low speed at 2.2°F (1.2°C) above set point. With the microprocessor set for dual probe control, the
The microprocessor will switch from cool to heat at set- microprocessor will select the supply air probe for con-
point. If box temperature rises when in low speed pull- trol when in Perishable Range operation and the return
air probe when in Frozen Range operation. Operating
down, the microprocessor will switch back to high
on the supply air probe in the Perishable Range mini-
speed at 2.7°F (1.5°C) above set point.
mizes top freezing while operating on the return air
After completing the pulldown, switching points are no lon- probe in the Frozen Range keeps the product at or
ger at a fixed temperature point. The microprocessor will slightly below setpoint.
monitor the rate of temperature reduction or increase, and
switch operation as required to limit overshoot. This
greatly increases the accuracy of the microprocessor.

4-1 62-11675
In the event of a probe failure on a single probe unit, 2. Defrost Air Switch Initiation
the unit will be shut down if operating in the Perishable The Defrost Air switch is of the diaphragm type and it
Range or switched to low speed cooling if operating in measures the change in air pressure across the evapo-
the Frozen Range. When operating in the Frozen rator coil. When the pressure differential is increased to
Range and on standby, the unit continues to operate in set point, due to the formation of ice on the coil surface,
cooling. An alarm will be generated to advise the oper- the switch closes to signal the microprocessor to place
ator of the probe failure. the unit in the defrost mode.
With dual probe control, the microprocessor will switch 3. Manual Defrost Initiation
over to the other probe in the event of an active probe
failure. This allows continued normal operation. The Defrost may be initiated manually by pressing the
appropriate alarm will be generated to advise the oper- MANUAL DEFROST key.
ator of the probe failure. 4. Fail Safe Defrost Termination

4.1.5 Fuel Heater Operation Should the defrost cycle not complete within 45 min-
utes or if the external defrost signal does not clear at
Energizing the heater relay provides a circuit to the fuel defrost termination, the microprocessor places the unit
heater thermostat (FHT). A thermostat (FHT), internal in the defrost override mode and the defrost cycle is
to the fuel filter bowl, closes to energizes the fuel terminated. The internal timer is reset for 1.5 hours, the
heater (FH) at temperatures below the cut in setting. Functional Parameter setting and Defrost Air switch
signal is ignored for defrost initiation. The manual
4.1.6 Defrost Mode defrost switch will override this mode and start a new
Defrost is an independent cycle (overriding cooling and 45 minute cycle. When defrost override is active, the
heating functions) to deice the evaporator as required. appropriate alarm will be indicated.
The controller displays “DF” during defrost mode on the
4.1.7 Unloading in Temperature Mode
right hand temperature display. The left hand display
will continue to display the setpoint. NOTE
Defrost may only be initiated if the defrost termination The unloader relay is locked in for a mini-
thermostat (DTT) is closed. The DTT closes, on a tem- mum of 2 minutes once it is energized due to
perature fall, at 37°F (3°C) to signal the microprocessor suction pressure.
that the coil temperature is low enough to allow the
There are two modes of unloader operation: tempera-
build up of frost. Defrost is terminated when the DTT
ture control and suction pressure control (960 only).
opens again, on a temperature rise, at 47°F (8°C) sig-
naling the microprocessor that the coil has been 1. Temperature Control - Temperature Control
warmed to the point that the frost buildup should have Within 1.4°F (0.8°C) of Setpoint
been removed.
a. Cool light (CL) or heat light (HL) illuminated
During defrost the unit enters the heat mode and the (depending on mode of operation).
evaporator fans are de-energized. This will prevent the
b. If in low speed cooling, unloader relays (UFR)
circulation of warm air to the load. If the unit is shut
may energize to unload compressor banks.
down for any reason during a defrost cycle (run relay is
Refer to Table 4–1.
de-energized) the microprocessor defrost cycle is ter-
minated and the unit will restart normally. c. In low speed heating, front unloader relay (UFR)
energizes to unload compressor bank.
For 960 units only, the defrost damper (if provided) is
closed at defrost start and is kept closed for 90 sec-
Table 4–1 Unloading in Temperature Mode
onds with heat on for 60 seconds after defrost has ter-
minated.
Cylinder

Cylinder

SETPOINT SETPOINT
1. Defrost Timer Initiation BELOW ABOVE
10°F (-12°C) 10°F (-12°C)
Timed defrost is controlled by the setting of Functional
Parameter FN0 and may be set for 1.5, 3, 6 or 12 Supra 960
hours. The microprocessor will place the unit into the
Cool High Speed 6
defrost mode each time the timer expires. The defrost
timer runs only when the defrost termination thermostat Cool High Speed 6 Cool Low Speed 4
is closed also, it does not accumulate time when the
unit is in the null mode. The defrost timer is reset to Heat Low Speed 4
zero whenever a defrost cycle is initiated.
Cool Low Speed 6 Heat Low Speed 6

Cool Low Speed 4 Heat High Speed 6

62-11675 4-2
2. Perishable Cooling Unloader Control 5. Suction Pressure Control (960 Only)

Diesel Diesel
During perishable cooling the unloader is energized The microprocessor will monitor suction pressure of the
when the temperature approaches setpoint. If a supply refrigeration system and ambient temperature and con-
probe is present the unloader is energized when the trol the unloader to maintain a maximum operating
supply temperature decreases 5.4°F (3°C) below set- pressure based on these two values (via a pressure
point. It will stay unloaded until the supply temperature transducer).
rises above setpoint. If a supply probe is not present For each operating mode (high speed engine, low speed
the unloader is energized when the return temperature engine, standby) a specific varipower equation exists.
decreases more than 9°F (5°C) above setpoint. It will
stay unloaded until the return temperature rises more For a given ambient temperature, if the suction pres-
than 14.4°F (8°C) above setpoint. The return probe sure is below the equation value the compressor will
logic is disabled for ambient temperature higher than run on all cylinders. If not, two cylinders will be
90°F (32.2°C). unloaded.

Standby The unloader is energized during engine or standby

motor start.
During perishable cooling the unloader is energized
when the control temperature reaches less than 2°F When operating in ambient temperatures below 90°F
(1.1°C) above setpoint. The unloader stay energized (32.2°C) the unloader will de-energize when the suc-
until the control temperature reaches 2.5°F (1.4°C) tion pressure falls below 27 psig for high speed or 36
above setpoint. psig for low speed.

3. Perishable Heating Unloader Control When operating in ambient temperatures above 90°F
(32.2°C) the unloader will de-energize when the suc-
Diesel tion pressure falls below the stated pressure on the
During perishable heating the front unloader is ener- graph. (Refer Figure 4.1)
gized when the control temperature increases to 0.9°F
(0.5°C) below setpoint. The unloader will stay ener- Figure 4.1 Suction Pressure Control - Diesel
gized until the control temperature decreases to 1.5°F
(0.8°C) below setpoint. ',(6(/23(5$7,21
68&7,2135(6685(681/2$',1*
NOTE
These switch points may vary slightly

depending on the amount of overshoot LOW SPEED
around set point. (UF)

Standby
During perishable heating the unloader is energized 
when the control temperature increases to 1.5°F SUCTION
(0.8°C) below setpoint. The unloader will stay ener- PRESSURE
gized until the control temperature decreases to 2°F (PSIG)  HIGH
(1.1°C) below setpoint. SPEED
 (UF)
4. Frozen Unloader Control

Diesel 
During frozen mode, heating is not allowed. The front      
unloader is energized when the control temperature AMBIENT TEMPERATURE ( F)
decreases to 1.5°F (0.8°C) above setpoint. The
unloader will stay energized until the control tempera- UF=FRONT UNLOADER ENERGIZED
ture reaches 2°F (1.1°C) above setpoint.
Standby
During frozen mode, heating is not allowed. The front
unloader is energized when the control temperature
decreases to 2°F (1.1°C) above setpoint. The unloader
will stay energized until the control temperature
reaches 2.5°F (1.4°C) above setpoint.

4-3 62-11675
Standby 4.2 Sequence of Operation
When operating in ambient temperatures below 90°F
4.2.1 Engine Drive
(32.2°C) the unloader will de-energize when the suc-
tion pressure falls below 27 psig. Refer to Section 8 for a schematic diagram of the unit
controls. To facilitate location of the components
When operating in ambient temperatures above 90°F referred to in the written text, the schematic has map
(32.2°C) the unloader will de-energize when the suc- coordinates added to the margins. These locations
tion pressure falls below the stated pressure on the have also been added to the legend. In order to provide
graph. (Refer Figure 4.2.) complete information, the following description is writ-
ten as if all options are installed. Indications of specific
Figure 4.2 Suction Pressure Control - Standby unit applicability and optional equipment are provided
on the schematic diagram. The microprocessor con-
67$1'%<23(5$7,21 trols operation of the various relays and components
68&7,2135(6685(681/2$',1* by completing or by breaking the circuit to ground.

To start the unit, place the RUN/STOP Switch (RSS) in
the RUN position and the cab command I/O Switch in
 FRONT UNLOADER the ON position.
SUCTION With the switches positioned, the ROAD key is pressed
PRESSURE
(PSIG) 
to begin the start process. Power flows from RSS
through fuse F2 to the Run Control Relay (RCR). RCR
is grounded by the microprocessor through the Door
 Switch Relay (DSR) and cab command to energize
      RCR. The RCR contacts close to provide power to the
AMBIENT TEMPERATURE ( F) control relays. Power to the Run Relay (RR) is depen-
dent on the High Pressure Switch (HPS) being closed.
If the high pressure switch is open, power will not be
High Ambient Control (860 Only)
applied to microprocessor terminal M1 and operation
The refrigeration system will control discharge pres- will not be allowed.
sure in both diesel and standby and will control the
Energizing RR closes a set of contacts to supply power
unloader in the following manner:
to the alternator (ALT), Run Solenoid (RS), Fuel Pump
Diesel (FP) and Fuel Heater Relay (FHR). RS energizes to
open the engine fuel rack, FP energizes to pump fuel to
At discharge pressures of 440 ± 10 psig (30 ± 0.7 bar) the injection pump and FHR energizes to close a set of
and higher the refrigeration system will be forced into contacts supplying power to the fuel heater thermostat.
unloaded operation until the discharge pressure is The fuel heater thermostat closes to energize the fuel
reduced to 367 ± 12 PSIG (25 ± 0.8 bar) heater at temperatures below the option setting. The
Standby engine is thus prepared for start up.

The refrigeration system is controlled by the Standby The microprocessor will now run the Auto Start
Unloader Front Relay (SUFR) and is always forced into Sequence (refer to Section 4.2.3) to start the engine.
loaded operation. The Glow Plug Relay (GPR) is energized to close a set
of contacts (SSC) and provide power to the Glow Plugs
4.1.8 Auto Diesel Restart (Option) (GP) as required to preheat the engine cylinders. The
Starter Solenoid Relay (SSR) will then be energized to
If AC power is lost for five minutes or more, configura- close a set of contacts and energize the Starter Sole-
tion 10 is active and TIME START is enabled, the die- noid (SS). Energizing SS closes a set of contacts to
sel engine will start and run until AC power is restored energize the Starter Motor (SM) and crank the engine.
and applied for five minutes. When the five minute
shutdown timer expires and AC power is present, the During cranking a signal is also supplied to micropro-
unit will shut down the diesel engine and restart the cessor terminal L2. Once the engine starts and and the
standby motor. If AC power is NOT present, the diesel alternator begins to produce power, the microprocessor
engine will operate as required. senses the power at terminal L3 an d the start
sequence is terminated. The microprocessor ignores
Once the unit has cycled off, it will remain off for the the Oil Pressure Switch (OP) signal for 15 seconds to
minimum off time of five minutes. This prevents rapid allow the engine time to develop sufficient pressure to
cycling due to changes in air temperature. Air tempera- close OP.
ture in the box changes rapidly but it takes time for the
product temperature to change. The unit will start in High Speed Cool with unloaders
energized (860 and 960) and fans de-energized. After 30
seconds the unit will revert to normal temperature control.

62-11675 4-4
Once the engine has started, the microprocessor will a ground path to energize the Diesel Electric Relay
complete the Defrost Transistor (DT) circuit to energize (DER). Energizing DER opens a set to contacts to
the Electric Fan Motor Relays (EFMR 1 through 3) break the circuit to the engine drive controls and closes
which close contacts to energize the Electric (Evapora- a set of contacts to allow power to the electric drive
tor) Fan Motors (EFM1 through 3). controls.
The microprocessor continues to monitor inputs to Power flows from RSS through fuse F2 to the Run
determine required modes of operation. The inputs Control Relay (RCR). RCR is grounded by the micro-
include the Suction Pressure Transducer (SPT), Water processor through the Door Switch Relay (DSR) and
temperature Sensor, Supply Air Sensor (SAS), and the cab command to energize RCR. The RCR contacts
Compressor Discharge Transducer (CDT). close to provide power to the control relays. Power to
the Run Relay (RR) is dependent on the High Pressure
As required, the microprocessor will take the following
Switch (HP1) being closed. If the high pressure switch
actions:
is open, power will not be applied to microprocessor
On Supra 860 and 960 units, when in the low speed terminal M1 and operation will not be allowed.
mode, the microprocessor also energizes the Unloader
Energizing RR closes a set of contacts to supply power
Front Relay (UFR). Energizing UFR closes a set of
through the motor Overload (OL) to the Motor Contac-
contacts to energize the compressor unloader (UF)
tor (MC1). Energizing MC1 closes it's contacts to start
deactivating two cylinders.
the Standby Motor (SBM).
For high ambient protection on Supra 860 units, the
On Supra 860 units, power is also supplied from the
unloader is controlled through the Compressor Clutch
DER contacts to energize the Standby Unloader Front
Relay (CCR). CCR is energized through a second dis-
Relay (SUFR). Energizing SUFR opens a set of nor-
charge pressure switch (HP2). If high pressure is below
mally closed contacts in the power line to the unloader
367 psig (25 bar) the compressor is in 4 cylinder opera-
preventing unloaded operation.
tion (2 cylinder for 960). If pressure is above 440 psig
(30 Bar) the compressor is in 4 or 6 cylinder operation. The unit will delay operating for 5 seconds, then will
revert to normal temperature control after this period.
On call for heat, the Heater Relay (HR1) is energized to
close a set of contacts and energize the hot gas bypass Once the motor starts the alternator begins to produce
solenoid valve (HGS2) and the hot gas 3-way valve power. The microprocessor senses the power at termi-
(HGS1) placing the unit in the heat mode. If the unit is nal L3 and it will complete the Defrost Transistor (DT)
equipped with hot water heat, the contactor will open circuit to energize the Electric Fan Motor Relays
the hot water heat solenoid valve. Units equipped with (EFMR 1 through 3). The relays close contacts to ener-
electric heat will energize the heater elements. gize the Electric (Evaporator) Fan Motors (EFM1
through 3).
On call for defrost, the microprocessor energizes the
hot gas bypass valve (HGS2) and the hot gas 3-way The microprocessor continues to monitor inputs to
valve (HGS1) in the same manner as in heat. Also, DT determine required modes of operation. The inputs
is de-energized, stopping the evaporator fan motors. include the Suction Pressure Transducer (SPT), Return
Air Sensor (RAS), Supply Air Sensor (SAS), and the
4.2.2 Standby Compressor Discharge Transducer (CDT) .
Refer to Section 8 for a schematic diagram of the unit As required, the microprocessor will take the following
controls. To facilitate location of the components actions:
referred to in the written text, the schematic has map
coordinates added to the margins. These locations On call for heat, the Heat Relay (HR) is energized to
have also been added to the legend. In order to provide close a set of contacts and energize the hot gas bypass
complete information, the following description is writ- solenoid valve (HGS2) and the hot gas 3-way valve
ten as if all options are installed. Indications of specific (HGS1) placing the unit in the heat mode. In the heat
unit applicability and optional equipment are provided mode the microprocessor also energizes the Evapora-
on the schematic diagram. The microprocessor con- tor Heat Relay (EHR). Energizing EHR closes a set of
trols operation of the various relays and components contacts to energize the Evaporator heat Contactor
by completing or by breaking the circuit to ground. (EHC) which closes it's contacts to energize the Evapo-
rator Heaters.
To start the unit, place the RUN/STOP Switch (RSS) in
the RUN position and the cab command I/O Switch in On call for defrost, the microprocessor energizes the
the ON position. hot gas bypass solenoid valve (HGS2) and the hot gas
3-way valve (HGS1) in the same manner as in heat.
With the switches positioned, the STANDBY key is Also, DT is de-energized, stopping the evaporator fan
p r e s s e d t o b e g i n t h e s t a rt p r o c e s s . W he n t h e motors.
STANDBY key is pressed, the microprocessor provides

4-5 62-11675
4.2.3 Auto Start Sequence If the engine has not started, a 15 second null cycle will
elapse before subsequent start attempts. The run relay
Refer to Section 8 for a schematic diagram of the unit
will remain energized during the null cycle.
controls. To facilitate location of the components
referred to in the written text, the schematic has map
Figure 4.3 Auto Start Sequence
coordinates added to the margins. These locations
have also been added to the legend. In order to provide
complete information, the following description is writ- REPEAT FIRST
ten as if all options are installed. Indications of specific + 5 Seconds
unit applicability and optional equipment are provided GLOW THIRD
on the schematic diagram. The microprocessor con- 15 Seconds ATTEMPT
trols operation of the various relays and components STOP
by completing or by breaking the circuit to ground. REPEAT FIRST
The Auto Start Sequence will begin once conditions for + five seconds
engine starting have been established, and the Run GLOW SECOND
ATTEMPT
Relay (RR) has been energized to provide power to the 15 Seconds
Run Solenoid (RS), Fuel Pump (FP) and Fuel Heater STOP
(FH). Refer to Section 4.2.1 for control circuit opera-
MAXIMUM
tion. The sequence consists of three start attempts
10 Seconds
each including a predetermined period with the glow Checked at CRANK
plugs energized and operation of the starter motor (see 2 Seconds*
Figure 4.3). FIRST
VARIABLE ATTEMPT
Five seconds after the run relay is energized, the 0 to 85 SECONDS GLOW
microprocessor will start the sequence by energizing GLOW
the glow plug relay (GPR) to supply power to the glow
plugs. See Table 4–2 for glow times. * Starter engagement time is increased to 20 seconds
when the water temperature sensor is at 32qF (0qC) or
If the Manual Glow Override Function Parameter is set below
to NORMAL, the glow time for the first start attempt will
vary in duration based on engine coolant temperature
as follows: Before the next starting sequence, the oil pressure and
Table 4–2 Default Glow Time alternator auxiliary input is checked to insure that the
engine is not running. For the second and third start
Engine Coolant Temperature Glow Time in attempts the glow time is increased by five seconds
Seconds over the glow time of the first attempt. The control
allows three consecutive start attempts before starting
Less than 32°F (0°C) 15 is locked out and the start failure alarm is activated.
33°F to 50°F (1°C to 10°C) 10 If battery voltage drops below 10 volts at any point
51°F to 77°F (11°C to 25°C) 5 during the Auto Start Sequence, the sequence will be
stopped and the start failure alarm is activated.
Greater than 78°F (26°C) 0
The system is configured for cooling mode for engine
The second and third start attempts have a glow time or standby start (default mode). Once unit is consid-
that is five seconds greater than the table amount. ered running it will maintain setpoint temperature by
switching between heat and cool.
If the Manual Glow Override Function Parameter is set
to ADD GLOW the additional time will be added to the When in the null mode two conditions will override nor-
first attempt. Actual time added to the second and third mal microprocessor off time and/or temperature con-
attempts will vary with ambient temperature. trol. If the unit is in the Engine Drive or Standby mode
and battery voltage falls below 12.2 volts, the engine or
After the glow time has expired, the starter solenoid
motor will be restarted to allow the alternator to
(SS) is energized to crank the engine. The engine will
recharge the battery. If the unit is in the Engine Drive
crank for 10 seconds [20 seconds if engine coolant
mode and the engine coolant temperature drops below
temperature is below 32°F (0°C)]or until engine opera-
34°F (1°C) the engine will be restarted.
tion is sensed by the microprocessor at alternator sig-
nal input at terminal L3. General operation sequences for cooling, null, and
heating are provided in the following paragraphs. The
microprocessor automatically selects the mode neces-
sary to maintain box temperature at setpoint.

62-11675 4-6
 Figure 4.4 560/660/760/860 Temperature Control Sequence - Continuous Mode

&RQWLQXRXV0RGH

'LHVHO 6WDQGE\

HS Cool
2.7 F (1.5 C)
0.5 F (1.2 C)
Cool
LS Cool
0.5 F (0.3 C) 0.5 F (0.3 C)
Perishable Perishable
setpoint setpoint
-0.5 F (ï0.3 C)
>10.4 F >10.4 F -0.5 F (-0.3 C)
LS Heat
(- 12 C) (-12 C) Heat
-2.2 F(-1.2 C)
HS Heat -2.7 F (-1.5 C)

HS Cool
3.6 F (2 C)
2.2 F (1.2 C)

Frozen LS Cool Frozen Cool

setpoint setpoint
>10.4 F (-12 C) >10.4 F (-12 C)

6XSUD 560/660/760/

4-7 62-11675
 Figure 4.5 560/660/760/860 Temperature Control Sequence - Start / Stop Mode

6WDUW6WRS0RGH

'LHVHO 6WDQGE\

START
START
3.6 F (2 C)
HS Cool 3.6 F (2 C)
2.7 F (1.5 C)
0.5 F (1.2 C)
Cool
LS Cool
0.5 F (0.3 C)
0.5 F (0.3 C) Perishable OFF
STOP -0.5 F
Perishable -0.5 F setpoint (-0.3 C)
setpoint (-0.3 C) >10.4 F Heat
>10.4 F LS Heat (-12 C)
(-12 C)
-2.2 F(-1.2 C) -3.6 F (-2 C)
-2.7 F (-1.5 C)
HS Heat
-3.6 F (-2 C) START
START

START
3.6 F (2 C) 3.6 F (2 C) 3.6 F
HS Cool
(2 C)
Cool
0.5 F (1.2 C)
LS Cool 0.5 F
(0.3 C)
Frozen
0.5 F (0.3 C)
setpoint
Frozen >10.4 F
setpoint (-12 C)
>10.4 F STOP
STOP
(-12 C)

6XSUD

62-11675 4-8
 Figure 4.6 960 Temperature Control Sequence - Continuous Mode

&RQWLQXRXV0RGH

'LHVHO 6WDQGE\

HS Cool ï 6 cyl
Cool - 6 cyl
2.7 F (1.5 C)
0.5 F (1.2 C) 2.5 F (1.4 C)

0.5 F (0.3 C) LS Cool - 4 cyl 2.0 F

Cool - 4 cyl (1.1 C)
Perishable Perishable 0.5 F
setpoint setpoint (0.3 C)
>10.4 F (-12 C) Heat - 4 cyl -0.5 F
-0.5 F >10.4 F (-12 C) (-0.3 C)
LS Heat - 4 cyl (-0.3 C) -1.4 F (-0.8 C)
-2.0 F
-2.2 F(-1.2 C) Heat - 6 cyl (-1.1 C)
HS Heat - 6 cyl -2.7 F (-1.5 C)

LS Cool ï 6 cyl

HS Cool - 6 cyl
3.6 F (2 C) Cool - 6 cyl
L S Co 1.4 F (0.8 C)
2.5 F (1.4 C) o l 6 cyl 0.5 F (1.2 C)
2.0 F
2.0 F (1.1 C)
(1.1 C)
Cool - 4 cyl
Frozen
Frozen
setpoint
setpoint LS Cool
< -12 C
>10.4 F (-12 C) 4 cyl
Cool - 4 cyl

6XSUD

4-9 62-11675
 Figure 4.7 960 Temperature Control Sequence - Start / Stop Mode

6WDUW6WRS0RGH

'LHVHO 6WDQGE\

START START
3.6 F (2 C) 3.6 F (2 C)
HS Cool - 6 cyl
2.7 F (1.5 C) Cool - 6 cyl
0.5 F (1.2 C) 2.0 F
(1.1 C) 1.4 F
LS Cool - 4 cyl
Cool - 4 cyl (0.8 C)
0.5 F (0.3 C)
0.5 F (0.3 C)
STOP Perishable
Perishable ï0.5 F -0.5 F
setpoint
setpoint (-0.3 C) (-0.3 C)
> -12 C Heat - 4 cyl
>10.4 F LS Heat - 4 cyl
(-12 C) -1.4 F (-0.8 C)
-2.0 F
-2.2 F(-1.2 C) -2.7 F (-1.5 C) Heat - 6 cyl
HS Heat - 6 cyl -3.6 F (-1.1 C)
-3.6 F (-2 C) (-2 C)
START START

START
3.6 F (2 C)
HS Cool 3.6 F (2 C)
Cool - 6 cyl
LS - 6 cyl
2.5 F (1.4 C) Co 2.5 F (1.4 C)
ol
6 cyl 0.5 F (1.2 C) 2.0 F
LS Cool 2.0 F (1.1 C)
Cool - 4 cyl
(1.1 C) 0.5 F
0.5 F (0.3 C) Frozen (0.3 C)
Frozen setpoint
setpoint >10.4 F (-12 C)
>10.4 F STOP
(-12 C) STOP

6XSUD

62-11675 4-10
 SECTION 5
Alarm Troubleshooting

Troubleshooting should begin with the first alarm that

! WARNING appears in the alarm list. The first alarm that appears is
the last alarm that was recorded. Other alarms in the
Advance microprocessor equipped units list may have contributed to the occurrence of the first
may start automatically at any time the alarm.
Main Power switch is not in the OFF posi- The check items in the troubleshooting guide are listed
tion. Also, the unit may be fitted with two in order of their likeliness of occurrence and ease of
way communication equipment that will testing. We recommend that you follow the order in
allow starting of the unit from a remote which they are presented; however, there may be times
location even though the switch is in the when situations or experience lead a to the use of a dif-
OFF position. ferent order. For example, if the trailer is loaded, con-
densing unit checks should be done first, even though
some evaporator section checks may be listed before
! WARNING them.
Be aware of HIGH VOLTAGE supplied at When the cause of the problem is corrected, it is not
the power plug or from the generator. necessary to continue through the remainder of the
When performing service or maintenance steps. Some active alarms will inactivate themselves
procedures: ensure any two way commu- automatically once the cause has been corrected.
nication is disabled in accordance with Alarms that do not inactivate themselves automatically
the manufacturer's instructions, ensure must be cleared manually. (See Section 3.4.9)
the Main Power switch is in the OFF posi-
When repairs are completed, run the unit through a
tion and, whenever practical, disconnect
Pretrip cycle and verify that no further alarms occur.
the high voltage source, lockout/tagout
the receptacle and disconnect the nega- When working on the refrigeration system, an accu-
tive battery connection. NEVER dis- rately calibrated manifold gauge set should always be
assemble the generator: HIGH MAG- installed. It is not necessary to connect an additional
NETIC FIELD INSIDE! This field can inter- high pressure gauge at the liquid line service valve.
f e r e w i t h c a r d i a c i m p la nt s s u c h a s The compressor suction pressure, compressor dis-
pacemakers and defibrillators. charge pressure and evaporator outlet pressure can be
read in the Unit Data.
5.1 Introduction
In high or low ambients it may be necessary to cool or
This section provides guidance for troubleshooting warm the refrigerated compartment temperature before
alarms. The alarm light will be illuminated when there is performing specific tests providing that the compart-
one (or more) alarm(s) stored in the microprocessor. ment is not loaded with perishable product.
Instructions for reviewing the alarm list is provided in
Section 5.2. 5.2 Alarm Display
Each alarm begins with an A followed by an alarm When an alarm is generated, the display will alternate
number and description. Alarms are listed in this guide between the default display (setpoint/air temperature)
(See Table 5–1) by alarm number in ascending order. and the active alarm(s). Each item will be displayed for
3 to 10 seconds and the display will continue to scroll
Before beginning to actually troubleshoot an alarm,
through the items until the alarms are cleared. Refer to
visually inspect the unit, in particular the area of the
Section 3.4.9 Alarm Reset for the procedure on reset-
unit that is causing a problem. In many cases the
ting alarms.
cause of the problem will be obvious once a visual
inspection is performed. For those cases where the The fault light (FL) will be illuminated when selected
cause of the problem is not obvious, this troubleshoot- alarms are generated. An alarm listing with indication
ing guide will be of assistance. of which alarms are accompanied by the fault light is
provided in Table 5–1. A description of the alarms is
provided in the following paragraphs.

5-1 62-11675
 Table 5–1 Alarm Display High Coolant Temperature Alarm
The English display for the High Coolant Temperature
ALARM DISPLAY ✔ = FAULT LIGHT ON
alarm is ENG HOT. The code display is AL1. This
CODE ENGLISH DESCRIPTION alarm is generated if the microprocessor senses cool-
ant temperature above 230°F (110°C). When this alarm
AL0 ENG OIL ✔ Low Oil Pressure
is generated, the fault light will illuminate and the
AL1 ENG HOT ✔ High Coolant Temperature engine will shut down.

AL2 HI PRESS ✔ High Discharge Pressure High Pressure Alarm

The English display for the High Pressure alarm is HI
AL3 STARTFAIL ✔ Auto Start Failure
PRESS. The code display is AL2. This alarm is gener-
AL4 LOW BATT ✔ Low Battery Voltage ated if the high pressure switch opens. When this
alarm is generated, the fault light will illuminate and the
AL5 HI BATT ✔ High Battery Voltage engine will shut down.
AL6 DEFR FAIL ✔ Defrost Override Start Failure Alarm
AL7 ALT AUX ✔ No Alternator Auxiliary The English display for the Start Failure alarm is
Output STARTFAIL. The code display is AL3. This alarm is
generated if the start sequence has completed and the
AL8 STARTER ✔ Starter Motor Fault
engine has failed to start. When this alarm is gener-
AL9 RA SENSOR ✔ Return Air Sensor Fault ated, the fault light will illuminate.

AL10 SA SENSOR Supply Air Sensor Fault If function parameter MAN OP (FN10 OFF) is selected
the start failure alarm will be generated if the engine is
AL11 WT SENSOR Coolant Temperature not started in five minutes.
Sensor
Low Battery Voltage Alarm
AL12 HIGH CDT ✔ High Discharge Temperature
The English display for the Low Battery Voltage alarm
AL13 CD SENSOR Discharge Temperature is LOW BATT. The code display is AL4. This alarm is
Sensor Fault generated if the battery voltage falls below 10 VDC.
When this alarm is generated, the fault light will illumi-
AL14 SBY MOTOR ✔ Standby Motor Fault
nate.
AL15 FUSE BAD ✔ Fuse Open
High Battery Voltage Alarm
AL16 SYSTEM CK ✔ Check Refrigeration System The English display for the High Battery Voltage alarm
is HIBATT. The code display is AL5. This alarm is gen-
AL17 DISPLAY Display
erated if the battery voltage rises to 17 VDC. When this
AL18 SERVICE 1 Maintenance Hour Meter 1 alarm is generated, the fault light will illuminate and the
engine will shut down.
AL19 SERVICE 2 Maintenance Hour Meter 2
Defrost Override Alarm
AL20 RAS OUT ✔ Main Compartment Out of
Range The English display for the Defrost Override alarm is
DEFR FAIL. The code display is AL6. This alarm is
AL21 2RA OUT ✔ Remote Compartment 2 Out generated if the defrost has been terminated by the 45
of Range minute timer. The fault light will not be illuminated by
AL22 3RA OUT ✔ Remote Compartment 3 Out this alarm.
of Range Alternator Auxiliary Alarm
AL23 NO POWER No AC Power When Unit Is The English display for the Alternator Auxiliary alarm is
In Standby ALT AUX. The code display is AL7. This alarm is gen-
erated if the alternator auxiliary signal is not present
Low Oil Pressure Alarm with the engine running. When this alarm is generated,
The English display for the Low Oil Pressure alarm is the fault light will illuminate.
ENG OIL. The code display is AL0. This alarm is gen- Starter Motor Alarm
erated if the microprocessor senses low oil pressure
The English display for the Starter Motor alarm is
any time after a short delay allowed at startup. When
STARTER. The code display is AL8.This alarm is gen-
this alarm is generated, the fault light will illuminate and
erated if the starter motor input signal is not present
the engine will shut down.
with starter solenoid energized. When this alarm is
generated, the fault light will illuminate.

62-11675 5-2
Return Air Sensor Alarm Fuse Alarm
The English display for the Return Air Sensor alarm is The English display for the Fuse alarm is “FUSE BAD”.
RA SENSOR. The code display is AL9. This alarm is The code display is AL15. This alarm is generated
generated if the return air sensor is open or shorted. when the FUSE input is sensed low. When this alarm is
generated, the fault light will illuminate.
If the microprocessor is set to allow operation on a sec-
ond sensor, it will switch control to that sensor. If the System Check Alarm
unit is not fitted with a second sensor or if the micropro- The English display for the System Check alarm is
cessor is not set to allow control on the second sensor, SYSTEM CK. The code display is AL16. This alarm is
one of two actions will be taken. generated when refrigerant system pressure is low.
1. If the unit is operating in the perishable range, The fault light will be illuminated by this alarm.
the unit will shut down. Display Alarm
2. If the unit is operating in the frozen range, the The English display for the Display alarm is DISPLAY.
unit will switch to low speed cool. The code display is AL17. This alarm is generated
when no communications exist between the main
When this alarm is generated, the fault light will illumi- board and the display. The fault light will not be illumi-
nate. nated by this alarm.
Supply Air Sensor Alarm Maintenance Hour Meter 1 Alarm
The English display for the Supply Air Sensor alarm is The English display for the Maintenance Hour Meter 1
SA SENSOR. The code display is AL10. This alarm is alarm is SERVICE 1. The code display is AL18. This
generated if the supply air sensor is open or shorted. alarm is generated when the designated hour meter is
This alarm will be disabled if the REM PROBE (FN4 A) greater than maintenance hour meter 1. The fault light
is selected in the controlling probe functional parame- will not be illuminated by this alarm.
ter. The fault light will not be illuminated by this alarm. Maintenance Hour Meter 2 Alarm
Coolant Temperature Sensor Alarm The English display for the Maintenance Hour Meter 2
The English display for the Coolant Temperature Sen- alarm is SERVICE 2. The code display is AL19. This
sor alarm is WT SENSOR. The code display is AL11. alarm is generated when the designated hour meter is
This alarm is generated if the coolant temperature sen- greater than maintenance hour meter 2. The fault light
sor is open or shorted. The fault light will not be illumi- will not be illuminated by this alarm.
nated by this alarm. Out Of Range Alarm
Compressor Discharge Temperature Alarm The English display for the Out Of Range alarm is OUT
The English display for the Compressor Discharge RANGE. The code display is AL20. This alarm is gen-
Temperature alarm is HIGH CDT. The code display is erated when the main compartment temperature is out-
AL12. This alarm is generated if the microprocessor side the designated range from set point. When this
senses discharge temperature above 310°F (155°C) alarm is generated, the fault light will illuminate.
for 3 minutes. When this alarm is generated, the fault Remote Compartment 2 Out of Range Alarm
light will illuminate.
The English display for the Remote Compartment 2 alarm
If the discharge temperature exceeds 350°F (177°C), is 2RAS OUT. The code display is AL21. This alarm is
the fault light will illuminate and the engine will be shut generated when the second compartment temperature is
down immediately. outside the designated range from set point. When this
alarm is generated, the fault light will illuminate.
Compressor Discharge Temperature Sensor Alarm
The English display for the Compressor Discharge Remote Compartment 3 Out of Range Alarm
Temperature Sensor alarm is CD SENSOR. The code The English display for the Remote Compartment 3 alarm
display is AL13. This alarm is generated if the sensor is is 3RAS OUT. The code display is AL22. This alarm is
open or shorted. The fault light will not be illuminated generated when the second compartment temperature is
by this alarm. outside the designated range from set point. When this
alarm is generated, the fault light will illuminate.
Standby Motor Overload Alarm
The English display for the Standby Motor Overload No Power for Standby Alarm
alarm is SBY MOTOR. The code display is AL14. This The display for the No Power alarm is NO POWER. This
alarm is generated if the MOL is open and the diesel/ alarm is generated when the unit is placed in the Standby
electric relay is energized (indicating standby mode). mode and there is no power to the power supply detector.

5-3 62-11675
 SECTION 6
Service

! WARNING
Unit may start automatically at any time even if the switch is in the OFF position. Use proper
lockout/tagout procedures before inspection/servicing. All unit inspection/servicing by prop-
erly trained personnel only.

! WARNING
Beware of V-belts and belt driven components as the unit may start automatically. Before ser-
vicing unit, make sure the RUN/ STOP Switch is in the STOP position. Also disconnect the neg-
ative battery cable.

! CAUTION
Unit uses R-404a and POE oil. The use of inert gas brazing procedures is mandatory for all Car-
rier Transicold refrigeration units; otherwise compressor failure will occur. For more informa-
tion Refer to Technical Procedure 985055300 Inert Gas Brazing.

NOTE
To avoid damage to the earth's ozone layer, use a refrigerant recovery system whenever removing
refrigerant. When working with refrigerants you must comply with all local government environmental
laws, U.S.A. EPA section 608.

6.1 Section Layout

Service procedures are presented herein under the following major sections:
• Scheduled Maintenance - Section 6.4.
• Pretrip Inspection - Section 6.3.
• Engine And Engine Related Systems Service- Section 6.5.
• Refrigerant System Service - Section 6.7.
• Compressor and Unloader Service - Section 6.11.
• Refrigerant System Component Service - Section 6.13.
• Electrical System Component Service - Section 6.22.

Refer to the Table of Contents to locate specific topics.

6.2 Scheduled Maintenance

For the most reliable operation and for maximum life, your unit requires regular maintenance. This includes oil and
filter changes, fuel and air filter replacement, coolant replacement and pretrip inspections. Maintenance is to be
performed in accordance with the procedures provided in Table 6–1.

6.3 Pre Trip Inspection

Pre trip inspection should be performed before every trip and at regular maintenance intervals. Pre trip procedures
are provided in Section 3.4.

6-1 62-11675
6.4 Maintenance Schedule
For the most reliable operation and maximum life, your unit requires regular maintenance. This includes oil and fil-
ter changes, fuel and filter replacement and coolant system maintenance. Maintenance should be performed on
the following schedule.
Table 6–1 Maintenance Schedule
ACTION/
SYSTEM OPERATION REFERENCE
SECTION

a. Daily Maintenance

Pre-Trip Inspection - before starting Check

Check Engine Hours Check
Check Engine Oil Level Check

b. Every 1500 Engine Hours

Unit Check belts for proper tension (Replace as required) 6.6

Check all mounting hardware for proper torque Check
Check battery terminals and fluid level Check
Check all bearings (idler, fan shaft, clutch, etc.) Check
Check all unit operations Check
Heat Check
Cool Check
Defrost Check
Check timer setting and function Check
Ensure fans stop (Damper door closes on 960 Check
Drain lines are clear Check
Terminates automatically Check

Engine Replace lube oil and filter 6.5.2

Replace fuel filter Check
Check engine cooling system 6.5.1
Check and clean fuel pump filter 6.5.4
Replace air filter cartridge 6.5.3
Check alternator brushes 6.5.6
Check and adjust rocker arms Check
Check engine speeds Check
560 High 2200-2250 / Low 1800-1850
660 High 2200-2250 / Low 1800-1850
760 High 2400-2450 / Low 1800-1850
860 High 2300-2350 / Low 1800-1850
960 High 2200-2250 / Low 1800-1850

Refrigeration Clean condenser and evaporator coils Service

System Check refrigerant level 6.10.4
Check compressor oil level 6.12.1

c. Every 12,000 Engine Hours

Engine Change anti-freeze and flush coolant system Service

Clean and adjust fuel injectors Service

These maintenance schedules are based on the use of approved oils and filters and regular pre-trip inspections of
the unit. Failure to follow the recommended maintenance schedule may affect the life and reliability of the refriger-
ation unit.
Maximum oil drain and filter replacement is once a year (every 12 months).
All units are shipped with Extended Life Coolant, replace every 12,000 hours or 5 years.

62-11675 6-2
6.5 Servicing Engine Related Components

6.5.1 Cooling System

The condenser and radiator can be cleaned at the same time. The radiator must be cleaned internally as well as
externally to maintain adequate cooling. See Figure 6.1.
The condenser and radiator are incorporated into a single assembly. The condenser fans draw the air through the
condenser and radiator coil. To provide maximum air flow the condenser fan belt should be checked periodically
and adjusted if necessary to prevent slippage.

! CAUTION
Use only ethylene glycol antifreeze (with inhibitors) in system as glycol by itself will damage
the cooling system. Always add premixed 50/50 antifreeze and water to radiator/engine. Never
exceed more than a 50% concentration of antifreeze. Use a low silicate antifreeze.

1. Remove all foreign material from the radiator/con denser coil by reversing the normal air flow. (Air is pulled
in through the front and discharges over the standby motor.) Compressed air or water may be used as a
cleaning agent. It may be necessary to use warm water mixed with any good commercial dish washer deter-
gent. Rinse coil with fresh water if a detergent is used.

2. Drain coolant by removing lower radiator hose and radiator cap.

3. Install hose and fill system with clean, untreated water to which three to five percent of an alkaline based
radiator cleaner should be added (six ounces - dry 151 grams to one gallon = 3.78 liters) of water.

4. Run engine 6 to 12 hours and drain system while warm. Rinse system three times after it has cooled down.
Refill system with water.

5. Run engine to operating temperature. Drain system again and fill with treated water/antifreeze. (see Caution
and refer to Section 1.2) NEVER POUR COLD WATER INTO A HOT ENGINE, however hot water can always
be added to a cold engine.

Figure 6.1 Coolant System

Thermostat
Water Coolant outlet
Temperature (hot side)
Sensor Pressure cap

Overflow Tank
Coolant pump

Coolant inlet
(cold side)

6-3 62-11675
6.5.2 Changing Lube Oil and Lube Oil Filter

! CAUTION
When changing the oil filter, the new filter should be primed with clean oil. If the filter is not
primed, the engine may operate for a period with no oil supplied to the bearings.

After warming up the engine, stop engine, remove Figure 6.2 Speed and Run Control Solenoids
drain plug from oil reservoir and drain engine lube oil.

Replace filter, lightly oil gasket on filter before installing 

and add lube oil. (Refer to Figure 2.6.1) Warm up  
engine and check for leaks.Replacing the Speed and 
Run Control Solenoids  

1. Run Solenoid (see Figure 6.2).

a. Remove spring (item 2) from the engine run

lever.
b. Disconnect wiring to solenoid. Remove clip
(item 5) from linkage rod (item 4). Remove

mounting hard ware and solenoid.

c. Attach linkage to new solenoid and install the 
 
clip to the linkage rod. Install the replacement
solenoid and mounting hardware loosely. Con- 
nect the ground wire and spring.
d. Energize the solenoid with a jumper wire con-
nected to a battery. Slide the solenoid far
1. Run Solenoid
enough back on the bracket to set the engine
2. Spring (Run Control)
run lever (item 3) against the stop. Tighten sole-
3. Engine Run Lever
noid mounting hard ware.
4. Linkage Rod (Run)
e. De-energize the solenoid. If the engine does not 5. Clip
shut off, repeat step 4 and adjust the solenoid
6. Speed Solenoid
forward slightly. When operating correctly,
7. Spring (Speed Control)
tighten solenoid mounting hardware and recon-
nect the positive wire. 8. Linkage Rod (Speed)
9. Engine Speed Lever
10. Boot

62-11675 6-4
2. Speed Control Solenoid (see Figure 6.2)

a. Remove spring (item 7) from the engine speed lever (item 9).
b. Disconnect wiring to solenoid. Disconnect linkage rod (item 8) from solenoid. Remove mounting hard ware
and solenoid.
c. Attach linkage to new solenoid and install the clip (item 5) to the linkage rod. Install the replacement sole-
noid and mounting hardware loosely. Connect the ground wire and spring.
d. Energize the solenoid with a jumper wire connected to a battery. Slide the solenoid far enough back on the
bracket to set the engine speed lever against the stop. Tighten solenoid mounting hardware.
e. Check engine speed. Speed may be verified using a strobe, Carrier Transicold P/N 0700206.
f. Disconnect the jumper wire and start the engine. The engine is in low speed. Refer to section 2.6 for engine
speed. Reconnect the jumper wire to energize the solenoid. The engine should increase to high speed. If
engine speed is not correct (engine lever against stop), stop engine and move the solenoid forward slightly.
Repeat procedure if adjustments need to be made.
g. When operating correctly, tighten solenoid mounting hardware and reconnect the positive wire.
h. If adjustment is not achieved by doing step 6, stop engine and remove linkage from solenoid. Remove boot
(item 10) from solenoid and pull solenoid shaft out (far enough to loosen jam nut on solenoid shaft). Ener-
gize solenoid for maximum force (pull) and then turn shaft clockwise to shorten.
i. De-energize solenoid, tighten shaft jam nut and re place boot. Connect linkage and repeat steps 5 and 6.

6.5.3 Engine Air Cleaner

1. Inspection

The air cleaner, hose and connections should be inspected for leaks. A damaged air cleaner or hose can seriously
affect the performance and life of the engine. If housing has been dented or damaged, check all connections imme-
diately.
Stop engine, remove air filter. Install new air filter.
When inspecting air cleaner housing and hoses, check the connections for mechanical tightness and look for frac-
tures in the inlet and outlet hoses. When leakage occurs and adjustment does not correct the problem, replace
necessary parts or gaskets. Swelled or distorted gaskets must always be replaced.

6-5 62-11675
6.5.4 Fuel Filter and Fuel Circuit

Figure 6.3 Fuel System

Restrictor fitting
Return tube Injection pump

Bleed port

Fuel filter
Fuel pump
Injectors
Supply line
Return line

1. Checking fuel circuit

a. The engine must run with bleed port slightly unscrewed. This indicates that the injection pump pres sure is
greater than 1.47 psig (0.1 bar). Check for air leakages and clean fuel lines if pressure isn't correct.

b. The electrical pump is designed to deliver 10.30 psig (0.7 bar). The fuel circuit flow rate in the return line is
about 1.32 gal (5 liters) per hour.

2. Changing the fuel filter

! CAUTION
When changing fuel filter, the new filter should be filled with clean fuel.

a. Remove cover, gasket and filter.

b. Wash filter in cleaning solvent and blow out with air pressure. Clean cover.

c. To Install reverse above steps.

d. After changing fuel filter, operate the electrical pump to bleed the fuel circuit properly before starting the
engine.

62-11675 6-6
 Figure 6.4 Electric Fuel Pump

3
4

1
2

1. Bowl
2. Gasket
3. Filter
4. Connector

3. Verify fuel pump capability

a. Remove fuel pump from the system. Connect a manometer to pump outlet. Energize fuel pump with a small
quantity of fuel.

b. At zero flow, the fuel pump should provide about 10.30 psig (0.7 bar) of pressure at the pump outlet.

• Pulsation frequency high - fuel circuit has low pres sure drop/high flow
• Pulsation frequency low (or null) - high pressure drop inside the circuit - low or zero flow Check for restriction
inside the circuit.Servicing

6.5.5 Glow Plugs

When servicing, the glow plug is to be fitted carefully into the cylinder head to prevent damage to glow plug. Torque
value for the glow plug is 6 to 11 ft lb (0.8 to 1.5 mkg).
Checking for a Defective Glow Plug

1. Method 1: Place an ammeter (or clip-on ammeter) in series with each glow plug and energize the plugs.
Each plug (if good) should show amperage draw of 8 to 10 amps.

2. Method 2: Disconnect the wire connection to the plug and test the resistance from the plug to a ground on
the engine block.

6.5.6 Alternator

! CAUTION
Observe proper polarity, reverse polarity will destroy the diodes. As a precaution, disconnect
positive terminal when charging.

The alternator and regulator are housed in a single assembly. A diagram for alternator troubleshooting or replace-
ment is provided below. See Figure 6.5.

1. Inspection
Verify tightness of connections. If excitation wire is disconnected the unit will display ALT AUX and battery will not
recharge during unit operation.

6-7 62-11675
2. Brushes (Refer to Maintenance Schedule 6.4)

a. Make sure battery terminals and alternator exciter cable are disconnected.

b. Remove the two screws holding the regulator.

c. Replace the brushes.

d. Reassemble the regulator.

3. Voltage control

a. Power up the unit.

b. Press UNIT DATA until voltage measurement out put is displayed.

Figure 6.5 Alternator (P/N 30-01114)

1 % % L

1. Positive Output Terminal (B-)

2. Battery Terminal (B+)
3. Ground Terminal (L)

62-11675 6-8
6.6 Servicing And Adjusting V-Belts

! WARNING
Beware of V-belts and belt driven components as the unit may start automatically.

6.6.1 Belt Tension Gauge

Use a belt tension gauge (Carrier P/N 0700203, see Figure 6.7) when replacing or adjusting V-belts. The belt tension
gauge provides an accurate and easy method of adjusting belts to their proper tension. Properly adjusted belts give
long lasting and efficient service. Too much tension shortens belt and bearing life, and too little tension causes slip-
page and excessive belt wear. It is also important to keep belts and sheaves free of any foreign material which may
cause the belts to slip.
The belt tension gauge can be used to adjust all belts. The readings which we specify for Carrier Transicold units
are applicable only for our belts and application, as the tension is dependent on the size of the belt and distance
between sheaves. When using this gauge, it should be placed as close as possible to the midpoint between two
sheaves. (See Figure 6.6)

Figure 6.6 V-Belt Arrangement

Standby
Motor
 

(QJLQH

Supra 860 and 960

Standby
 Motor
 

(QJLQH

Supra 560/660 and 760

The V-belts must be kept in good condition with the proper tension to provide adequate air movement across the
coils.
When installing any new belts, preset the tension to the setting specified in the New Install Tension column. After
initial run in, check the tension; it should settle out to the setting specified in the Running Tension column. If the run
tension is below the Running Tension range, re-tighten the belt to a value within this range. Refer to Table 6–2.

6-9 62-11675
 Table 6–2 Belt Tension (See Figure 6-7)

New Install Running

BELTS Tension Tension
(ft./lbs) (ft./lbs)

Water pump 30 to 50

Engine to
100 to 120 80 to 90
Compressor

Alternator 50 40 to 50

Standby Motor to
100 to 120 80 to 90
Compressor

Figure 6.7 Belt Tension Gauge (Part No. 0700203)

6.6.2 Alternator V-Belt

1. Make sure negative battery terminal is disconnected.

2. Place V-belt on alternator sheave and driving pulley.

3. Pivot alternator to place tension on belt using hand force only. Do not use pry bar or excessive force as it
may cause bearing failure. For correct belt tension see Table 6–2. Tighten pivot and adjustment bolts.

6.6.3 Water Pump Belt

! WARNING
When working with belts, beware of pinch points.

The water pump belt is driven by the diesel engine crankshaft pulley. Two water pump belt designs are employed in
the Supra units; the V-belt with an automatic belt tensioner to ensure the correct tension and the poly V-belt that
needs no tensioner.
To change the water pump V-belt, proceed as follows:

1. To compress the tensioner spring, place a threaded bolt or rod into hole and turn clockwise. This will draw
the spring up and slacken V-belt for easy removal.

2. After replacing V-belt, remove the bolt to release the spring to return the idler to its correct tension.

! WARNING
Beware of moving poly V-belt and belt driven components.

62-11675 6-10
To replace the poly V-belt, perform the following steps:

1. Using the proper size socket, slowly rotate the crank by turning the crank pulley nut. At the same time, use a
flat, blunt object to guide the belt off the crank pulley. Be careful not to damage grooves on the pulley.

2. Replace the poly V-belt by positioning the belt on the water pump pulley, and while rotating the engine (as in
step 1), use a flat, blunt object to guide the belt onto the crank pulley. Be careful not to damage grooves on
the pulley or belt.

6.6.4 Standby Motor-Compressor V-Belt

1. Remove alternator V-belt. (Refer to Section 6.6.2)

2. Loosen the V-belt idler securing bolt (22 mm).

3. Replace V-belt and alternator V-belt. Position the idler to correct belt tension. Tighten the idler retaining bolt.

6.6.5 Engine-Compressor V-Belts

1. To allow for easy removal, installation and adjustment of the V-belts, it is recommended that the muffler be
dis connected from the muffler bracket and moved.

2. Remove alternator V-belt. (Refer to Section 6.6.2)

3. Remove the standby motor-compressor V-belt. (Refer to Section 6.6.4)

4. Loosen belt idler bolt (24 mm). Move idler to remove V-belts.

5. Replace V-belts. Position the idler to the correct belt tension. Tighten the idler retaining bolt.

6.7 Installing Manifold Gauge Set

A manifold gauge/hose set is required for service of models covered within this manual. The manifold gauge/hose
set is available from Carrier Transicold. (Carrier Transicold P/N 07-00314-00, which includes items 1 through 4,
Figure 6.8). To perform service using the manifold gauge/hose set, do the following:

6.7.1 Preparing Manifold Gauge/Hose

1. If the manifold gauge/hose set is new or was exposed to the atmosphere it will need to be evacuated to
remove contaminants and air as follows:

2. Connect high and low side hoses to blank connections on back of manifold gauge set and midseat both
hand valves.

3. Connect the yellow hose to a vacuum pump and an R-404A cylinder.

4. Evacuate to 10 inHg (254 mmHg) and then charge with R-404A to a slightly positive pressure of 1.0 psig
(0.07 bar).

5. Front seat both manifold gauge set hand valves and disconnect from cylinder. The gauge set is now ready
for use.

6.7.2 Connecting Manifold Gauge/Hose Set

To connect the manifold gauge/hose set for reading pressures, do the following:

1. Remove service valve stem cap and check to make sure it is backseated. Remove access valve cap.

2. Connect the refrigeration hose (see Figure 6.8) to the access valve.

3. Read system pressures.

4. Repeat the procedure to connect the other side of the gauge set.

6-11 62-11675
 Figure 6.8 Manifold Gauge Set

Low Pressure 1 High Pressure

Gauge Gauge

Opened Closed
(Backseated ) (Frontseated)
Hand Valve Hand Valve

To Low Side To High Side

3
Blue 2
3
Red

3
4 2 Yellow 4

1. Manifold Gauge Set

2. Hose Fitting
3. Refrigeration and/or Evacuation Hose
4. Hose Fitting w/core Depressor

6.7.3 Removing the Manifold Gauge Set

1. While the compressor is still ON, backseat the high side service valve.

2. Midseat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge set to be
drawn down to low side pressure. This returns any liquid that may be in the high side hose to the system.

! CAUTION
To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suc-
tion pressure before disconnecting.

3. Backseat the low side service valve. Frontseat both manifold set hand valves. Remove the refrigeration
hoses from the access valves.

4. Install both service valve stem caps (finger tight only).

62-11675 6-12
6.8 Pumping the Unit Down or Removing the Refrigerant Charge

NOTE
To avoid damage to the earth's ozone layer, use a refrigerant recovery system whenever removing
refrigerant.

6.8.1 Pumping the Unit Down

To service the filter-drier, expansion valve, CPR valve or evaporator coil, pump most of refrigerant into condenser
coil and receiver as follows:
1. Backseat suction and discharge service valve (turn counterclockwise) to close off gauge connection and
attach manifold gauges to valves.
2. Open valves two turns (clockwise). Purge gauge line.
3. Close the receiver service valve by turning clockwise. Start unit and run in high speed cooling. Place RUN/
STOP Switch in the STOP position when unit reaches 0.1 kg/cm2 (1 psig).
4. Frontseat (close) suction service valve and the refrigerant will be trapped between the compressor suction
service valve and the receiver service valve.
5. Before opening up any part of the system, a slight positive pressure should be indicated on the pressure
gauge.
6. When opening up the refrigerant system, certain parts may frost. Allow the part to warm to ambient temperature
before dismantling. This avoids internal condensation which puts moisture in the system.
7. When service has been completed. Open (backseat) the receiver service valve and midseat suction service
valve.
8. Leak check connections with a leak detector. (Refer to Section 6.9)
9. Start the unit in cooling and check for noncondensibles.
10. Check the refrigerant charge. (Refer to Section 6.10.4)

NOTE
Store the refrigerant charge in an evacuated container if the system must be opened be tween the
compressor discharge valve and receiver.

NOTE
Whenever the system is opened, it must be evacuated and dehydrated. (Refer to Section 6.10)

6.8.2 Removing the Refrigerant Charge

Connect a refrigerant recovery unit and a clean refrigerant recovery cylinder to the unit to remove refrigerant
charge. Refer to instruction provided by the manufacture of the refrigerant recovery system.

6-13 62-11675
6.9 Refrigerant Leak Checking

6.9.1 Standard Leak Check

If system was opened and repairs completed, leak check the unit.

1. The recommended procedure for finding leaks in a system is with an electronic leak detector (Carrier p/n 07-
00295-00). Testing joints with soapsuds is satisfactory only for locating large leaks.

2. If system is without refrigerant, charge system with refrigerant to build up pressure between 2.1 to 3.5 kg/
cm2 (30 to 50 psig). Remove refrigerant cylinder and leak check all connections.

NOTE
Use only the correct refrigerant to pressurize the system. Any other gas or vapor will contaminate the
system which will require additional purging and evacuation of the high side (dis charge) of the sys-
tem.

3. Remove refrigerant using a refrigerant recovery system and repair any leaks. Evacuate and dehydrate the
unit. (Refer to Section 6.10) Charge unit with refrigerant. (Refer to Section 10.)

6.9.2 Leak Check Using Pressurized Dry Nitrogen

Under most conditions, the use of a Halogen leak detector is sufficient to find the refrigerant leak in the system.
However, there may be times when additional pressure is required to pinpoint the leak. In this case, dry nitrogen is
recommended to pressurize the system. One should never use pressurized air or other gases. The following
instructions are the optimal method for leaking checking with pressurized nitrogen.

! WARNING
Unit may start automatically at any time even if the switch is in the OFF position. Use proper
lockout/tagout procedures before inspecting/servicing. All unit inspection/servicing may be
done my properly trained personnel only.

! CAUTION
Before performing any work, ensure the unit start-run off switch (SROS) is in the OFF position,
the negative battery cable is disconnected, and any external shore power is removed. Proper
lockout / tag out procedures MUST be followed.

1. Connect manifold gauge set to the refrigeration unit. A three-point connection is recommended - compres-
sor suction and discharge service ports, as well as the receiver tank outlet service valve (King valve).

NOTE
When possible, place the unit in SERVICE MODE via the microprocessor.

2. Recover remaining refrigerant from the system.

3. Add one pound of refrigerant back into the system. This amount of refrigerant is sufficient to activate the hal-
ogen leak detector.

4. Connect the service hose to an approved nitrogen pressure regulator. See Figure 6.9 for an example of a
nitrogen regulator.

62-11675 6-14
 Figure 6.9 Nitrogen Pressure Regulator

5. Close the regulator (turn fully counterclockwise) to prevent any pressure from being added to the system.

6. Open the nitrogen cylinder and gradually open the regulator (turn clockwise) until the outlet pressure gauge
reads 20 to 150 psi. This is a sufficient amount of pressure to find any leak.

7. Open the manifold gauge set and allow pressure to stabilize between the nitrogen bottle and the refrigera-
tion unit.

8. Once the pressure has stabilized, close off the manifold gauge set and nitrogen cylinder. Disconnect the
service hose from the nitrogen cylinder.

9. Proceed with using the halogen leak detector around solder joints or potential leak points. Applying a soapy
solution may be necessary to pin point the source of the leak.

10. After the leak is detected, remove the nitrogen from system prior to performing any repairs.

11. When all leaks have been repaired, follow proper evacuation and charge procedures.

6-15 62-11675
6.10 Evacuation And Dehydration 00176-11) and a good vacuum indicator such as
a thermocouple vacuum gauge (vacuum indica-
6.10.1 General tor). (Carrier p/n 07-00414-00).
Moisture can seriously damage refrigerant systems.
The presence of moisture in a refrigeration system can NOTE
have many undesirable effects. The most common are Use of a compound gauge is not recom-
copper plating, acid sludge formation, freezing-up of mended because of its inherent inaccuracy.
metering devices by free water, and formation of acids,
3. Keep the ambient temperature above 60°F
resulting in metal corrosion.
(15.6°C) to speed evaporation of moisture. If
6.10.2 Preparation a m b i e n t t e m p e r a t u r e i s l o w er t h a n 6 0 ° F
(15.6°C), ice might form be fore moisture
1. Evacuate and dehydrate only after pressure removal is complete. Heat lamps or alternate
leak test. (Refer to Section 6.9) sources of heat may be used to raise system
temperature.
2. Essential tools to properly evacuate and dehy-
drate any system include a good vacuum pump
(5 cfm = 8m3H volume displacement, P/N 07-

Figure 6.10 Vacuum Pump Connection







 








1. Refrigerant Recovery Unit 7. Evaporator Coil

2. Refrigerant Cylinder 8. Receiver Service Valve
3. Evacuation Manifold 9. Condenser Coil
4. Valve 10. Suction Service Valve
5. Vacuum Pump 11. Discharge Service Valve
6. Electronic Vacuum Gauge

62-11675 6-16
6.10.3 Evacuation and Dehydrating System

1. Remove refrigerant using a refrigerant recovery system.

2. The recommended method to evacuate and dehydrate the system is to connect three evacuation hoses (as
shown in Figure 6.10) to the vacuum pump and refrigeration unit. Do not use standard service hoses, as
they are not suited for evacuation purposes. Also, as shown, connect a evacuation manifold, with evacua-
tion hoses only, to the vacuum pump, electronic vacuum gauge, and refrigerant recovery system.

3. With the unit service valves closed (back seated) and the vacuum pump and electronic vacuum gauge
valves open, start the pump and draw a deep vacuum. Shut off the pump and check to see if the vacuum
holds. This operation is to test the evacuation setup for leaks, repair if necessary.

4. Midseat the refrigerant system service valves.

5. Then open the vacuum pump and electronic vacuum gauge valves, if they are not already open. Start the
vacuum pump. Evacuate unit until the electronic vacuum gauge indicates 2000 microns. Close the elec-
tronic vacuum gauge and vacuum pump valves. Shut off the vacuum pump. Wait a few minutes to be sure
the vacuum holds.

6. Break the vacuum with clean dry refrigerant. Use refrigerant that the unit calls for. Raise system pressure to
approximately 2 psig.

7. Remove refrigerant using a refrigerant recovery system.

8. Repeat steps 5 through 7 one time.

9. Evacuate unit to 500 microns. Close off vacuum pump valve and stop pump. Wait five minutes to see if vac-
uum holds. This checks for residual moisture and/ or leaks.

10. With a vacuum still in the unit, the refrigerant charge may be drawn into the system from a refrigerant con-
tainer on weight scales. The correct amount of refrigerant may be added by observing the scales. (Refer to
Section 10.)Charging The Refrigeration System

! CAUTION
Refrigerant R-404a is a blend. Charging as a vapor will change the properties of the refrigerant.
Only liquid charging through the receiver service valve is acceptable.

6.10.4 Checking the Refrigerant Charge

1. Start unit in cooling mode and run approximately ten minutes.

2. Partially block off air flow to condenser coil so discharge pressure rises to 210 psig (14.8 kg/cm2).

3. The unit is correctly charged when the lower receiver sight glass is full and no refrigerant is in the upper
receiver sight glass.

6.10.5 Installing a Complete Charge (See Figure 6.11)

1. Dehydrate unit and leave in deep vacuum. (Refer to Section 6.10)

2. Place refrigerant cylinder on scale and connect charging line from cylinder to the receiver service valve.
Purge charging line at outlet valve.

3. Note weight of refrigerant cylinder.

4. Open liquid valve on refrigerant cylinder. Open the receiver service valve half way and allow the liquid refrig-
erant to flow into the unit until the correct weight of refrigerant has been added as indicated by scales. Cor-
rect charge will be found in Section 2.6.

5. When refrigerant cylinder weight (scale) indicates that the correct charge has been added, close liquid line
valve on cylinder and backseat the receiver service valve.

6-17 62-11675
 Figure 6.11 Adding A Complete Charge

3 1
5

1. Suction Valve (Low Side)

2. Manifold Gauge Set
3. Discharge Valve (High Side)
4. Refrigerant Cylinder
5. Dead Head Port

62-11675 6-18
6.10.6 Adding A Partial Charge (See Figure 6.12) 1. Place drum of refrigerant on scale and note
weight. Backseat discharge and suction service
valves and install a manifold gauge set in order
! CAUTION to monitor system. Purge lines. Connect the dis-
charge gauge of a second manifold test set to
Refrigerant R-404A is a blend. Charging
the receiver service valve. Connect the suction
as a vapor will change the properties of
pressure hose to manifold dead head port. Con-
the refrigerant. Only liquid charging
nect a charging line between the center tap of
through the receiver service valve is
the second gauge set and refrigerant drum. Mid-
acceptable.
seat discharge knob. Open the liquid valve on
drum and purge all hoses. Frontseat discharge
NOTE
knob. See Figure 6.12.
The ambient (air entering the condenser) air
temperature should be above 40°F (4.4°C). 2. Start the unit with the road compressor turning
at 2400 rpm.
Figure 6.12 Adding A Partial Charge
3. Check the sight glass to determine charge. See
Section 6.10.4. If undercharged, proceed with
step 4.

4. Front seat the receiver service valve. Monitor

the second set of manifold gauges. When the
receiver service valve pressure drops below the
pressure in the refrigerant drum, midseat the
manifold gauge set dis charge valve and allow
liquid refrigerant to flow into the system.
5. While monitoring the sight glass, carefully weigh
refrigerant into the system. It is not possible to
accurately determine when the system is full
because unit is in discharge state; therefore,
never allow more than 1 lb. (0.45 kg) of refriger-
ant into system at a time.
6. After monitoring 1 lb. (0.45 kg) of refrigerant into
the system, close the valve of the manifold
2
1 2 gauge set connected to the receiver service
5 valve. Open the receiver service valve and allow
1
the system to balance out to determine charge.
7. Follow the procedures of Section 6.10.4 and
repeat above procedure as required to clear the
sight glass.

4 3 3 8. Start unit and check for non-condensables.

1. Suction Valve (Low Side)

2. Discharge Valve (High Side)
3. Manifold Gauge Set
4. Refrigerant Cylinder
5. Dead Head Port

6-19 62-11675
6.11 Replacing the Compressor 4. Remove vacuum pump lines and install manifold
gauges.

! WARNING 5. Check refrigerant level (Refer to Section 6.10.4)

Ensure power to the unit is OFF and NOTE

power plug is disconnected or vehicle It is important to check the compressor oil
engine is OFF and negative battery cable level of the new compressor and fill if
is disconnected before replacing the necessary.
compressor.
6. Check compressor oil level. (Refer to Section
6.11.1 Removing 6.12) Add oil if necessary.
If compressor runs, pump down the unit. (Refer to Sec- 7. Check refrigerant cycles.
tion 6.8.1)
If compressor is inoperative and unit still has refrigerant 6.12 Compressor Oil Level
pressure, frontseat suction and discharge service
valves to isolate the compressor from the unit. 6.12.1 Checking Oil Level

1. Recover refrigerant from compressor with a 1. Operate the unit in high speed cooling for at
refrigerant recovery system. least 20 minutes.

2. Remove bolts from suction and discharge ser- 2. Check the oil sight glass on the compressor to
vice valve flanges. ensure that no foaming of the oil is present after
20 minutes of operation. If the oil is foaming
3. Disconnect wiring to compressor discharge tem- excessively after 20 minutes of operation, check
perature sensor (CDT), suction pressure trans- the refrigerant system for floodback of liquid
ducer (SPT) and the wiring to the high pressure refrigerant. Correct this situation before perform-
switch (HP). ing step 3.

4. Release idler pulleys and remove belts. 3. Check the level of the oil in the sight glass with
the compressor operating. The correct level
5. Remove the four bolts holding the compressor should be between bottom and 1/4 of the sight
to the power tray. Remove the compressor from glass. If the level is above 1/4, oil must be
chassis. removed from the compressor. To remove oil
from the compressor, follow step 6.12.4. If the
6. Remove the pulley from the compressor.
level is below sight glass, add oil to the com-
7. Drain oil from defective compressor before ship- pressor following 6.12.2.
ping.
6.12.2 Adding Oil with Compressor in System
6.11.2 Installing Two methods for adding oil are the oil pump method
1. To install the compressor, reverse the procedure and closed system method.
out lined when removing the compressor. Refer Oil Pump Method
to Section 2.6.5 for torque values.
One compressor oil pump that may be purchased is a
NOTE Robinair, P/N 14388. This oil pump adapts to a one
U.S. gallon (3.785 liters) metal refrigeration oil con-
The service replacement compressor is sold
tainer and pumps 2-1/2 ounces (0.0725 liters) per
without shutoff valves (but with valve pads).
stroke when connected to the suction service valve
Customer should retain the original capacity
port. Also there is no need to remove pump from can
control valves for use on replacement com-
after each use.
pressor. Check oil level in service replace-
ment compressor. (Refer to sections 2.6.2, When the compressor is in operation, the pump check
and 6.12) valve prevents the loss of refrigerant, while allowing
servicemen to develop sufficient pressure to overcome
2. Attach two lines (with hand valves near vacuum the operating suction pressure to add oil as necessary.
pump) to the suction and discharge service
valves. Dehydrate and evacuate compressor to Backseat suction service valve and connect oil
500 microns (29.90 Hg vacuum = 75.9 cm Hg charging hose to port. Crack the service valve and
vacuum). Turn off valves on both lines to pump. purge the oil hose at oil pump. Add oil as necessary.

3. Fully open (backseat) both suction and dis-

charge service valves.

62-11675 6-20
Closed System Method Figure 6.13 Compressor
In an emergency where an oil pump is not available, oil
may be drawn into the compressor through the suction  
service valve. 6 


! CAUTION
Extreme care must be taken to ensure the 
manifold common connection remains 
immersed in oil at all times. Otherwise air and 
moisture will be drawn into the compressor.

Connect the suction connection of the gauge manifold  
to the compressor suction service valve port, and 4-Cylinder 2-Cylinder
immerse the common connection of the gauge mani-
fold in an open container of refrigeration oil. Crack the
suction service valve and gauge valve to vent a small
amount of refrigerant through the common connection 
and the oil to purge the lines of air. Close the gauge 6
manifold valve.
With the unit running, frontseat the suction service  
valve and pull a vacuum in the compressor crankcase.
SLOWLY crack the suction gauge manifold valve and
oil will flow through the suction service valve into the
compressor. Add oil as necessary.

6.12.3 Adding Oil to Service Replacement Com-

pressor

Service replacement compressors may or may not be
shipped with oil.
If compressor is without oil: Add correct oil charge by  6-Cylinder
removing the oil fill plug (See Figure 6.13).

6.12.4 Remove oil from the compressor: 1. Suction Service Valve

1. Close suction service valve (frontseat) and 2. Discharge Service Valve
pump unit down to 2 to 4 psig (0.1 to 0.3 kg/ 3. Oil Level Sight Glass
cm 2 ). Frontseat discharge service valve and 4. Oil Drain Plug
slowly bleed remaining refrigerant. 5. Oil Fill Plug
6. Unloader Assembly
2. Remove the oil drain plug from compressor and
drain the proper amount of oil from the compres-
sor. Replace the plug securely back into the com-
pressor. 6.13 Compressor Unloader Valve (860 and 960
only)
3. Open service valves and run unit to check oil
The compressor unloader (located on the compressor
level, repeat as required to ensure proper oil
cylinder head) is controlled by relay UFR and the tem-
level.
perature controller.

6.13.1 Checkout Procedure

! WARNING 1. Connect manifold gauges to the compressor
Since refrigerant traps a certain quantity suction and discharge service valves and start
of oil, to avoid oil loss during mainte- unit in cooling with the trailer temperature at
nance, add 50 cc of POE oil to the refrig- least 5°F (2.8°C) above set point and the com-
eration system when any evacuation is pressor will be fully loaded (unloader coil de-
performed. energized). Note suction pressure.
2. Remove wiring from the unloader coil. Place
electrical tape over wire terminals.

6-21 62-11675
 3. Set controller upscale (cooler to warmer). This Figure 6.14 Unloader Solenoid Valve
mechanically simulates falling temperature.
Approximately 2°F (1.1°C) below box tempera- 
ture the unloader coil will energize. Note suction
pressure, a rise of approximately 3 psig (0.2 bar) 
will be noted on the suction pressure gauge. 

4. Reconnect wiring on the unloader. 

5. Reverse the above procedure to check out com- 
pressor loading. Suction pressure will drop with 
this test.  
 
NOTE 
If any unloader coil energizes and the suc- 
tion pressure does not change, the unloader 
assembly must be checked.

6.13.2 Solenoid Coil Replacement

NOTE  5HWDLQHU  3OXQJHU6SULQJ

The coil may be removed without pumping  &RLO$VVHPEO\  3OXQJHU$VVHPEO\
 ,QVWDOODWLRQ5HPRYDO  *DVNHW
the unit down.
7RRO  9DOYH%RG\
1. Disconnect leads. Remove retainer. Lift off coil.  (QFORVLQJ7XEH  *DVNHW
(See Figure 6.14) &ROODU  %ROW
 k2l5LQJ  *DVNHW%ROW
2. Verify coil type, voltage and frequency of old and  (QFORVLQJ7XEH  3LVWRQ5LQJ
new coil. This information appears on the coil hous-
ing. 6.14 Checking & Replacing Filter-Drier
3. Place new coil over enclosing tube, retainer and Check Filter-Drier
connect wiring.
Check for a restricted or plugged filter-drier by feeling
6.13.3 Replacing Solenoid Valve Internal Parts the liquid line inlet and outlet connections of the drier
cartridge. If the outlet side feels cooler than the inlet
1. Pump down the unit. Frontseat both service side, then the filter-drier should be changed.
valves to isolate the compressor.
Replace Filter-Drier
2. Remove coil retainer (see Figure 6.14), and 1. Pump down the unit per Section 6.8. Remove
coil. bracket, then replace drier.
3. Remove enclosing tube collar (item 4) using 2. Check refrigerant level. (Refer to Section
installation/removal tool supplied with repair kit 6.10.4)
(item 3).
6.15 Checking & Replacing High Pressure Switch
4. Check plunger for restriction due to: (a) Cor-
roded or worn parts; (b) Foreign material lodged 6.15.1 Replacing High Pressure Switch
in valve; (c) Bent or dented enclosing tube. 1. Pump down the unit. (Refer to Section 6.8)
Frontseat both suction and discharge service
5. Install new parts. Do not over tighten enclosing
valves to isolate compressor.
tube assembly. Torque to a value of 100 inch
pounds (1.15 mkg). 2. Slowly release compressor pressure through the
service valve gauge ports to refrigerant recovery
6. Remove supplied installation/removal tool. device.
Install coil, voltage plate, and retainer.
3. Disconnect wiring from defective switch. The
7. Evacuate and dehydrate the compressor. high pressure switch is located near the top of
the compressor.
4. Install new cutout switch after verifying switch
settings.
5. Evacuate and dehydrate the compressor. (Refer
to Section 6.11)

62-11675 6-22
6.15.2 Checking High Pressure Switch
NOTE
Do not use a nitrogen cylinder without a pressure regu- The magnehelic gauge may be used in any
lator. Cylinder pressure is approximately 2350 psi (165 position, but must be re-zeroed if position of
kg/cm 2 ). Do not use oxygen in or near a refrigerant gauge is changed from vertical to horizontal
system as an explosion may occur. (See Figure 6.15) or vice versa. USE ONLY IN POSITION
FOR WHICH IT IS CALIBRATED.
Figure 6.15 Setup for Testing High Pressure
Switch 2. With air switch in vertical position, connect high
pres sure side of magnehelic gauge to high side
connection of air switch. (See Figure 6.16)
1
3. Install tee in pressure line to high side connection.
4
Tee should be approximately halfway between
gauge and air switch or an improper reading may
2 5
result.
4. Attach an ohmmeter to the air switch electrical
con tacts to check switch action.
3 6
NOTE
Use a hand aspirator (P/N 07-00177-01),
since blowing into tube by mouth may cause
an incorrect reading.
5. With the gauge reading at zero, apply air pres-
1. Cylinder Valve and Gauge sure very slowly to the air switch. An ohmmeter
will indicate continuity when switch actuates.
2. Pressure Regulator
3. Nitrogen Cylinder 6. Refer to Section 2.6.3 for switch settings. If switch
4. Pressure Gauge (0 to 400 psig = 0 to 28 kg/cm2) fails to actuate at correct gauge reading, adjust
5. Bleed-Off Valve switch by turning adjusting screw clockwise to
6. 1/4 Inch Connection increase setting or counterclockwise to decrease
setting.
7. Repeat checkout procedure until switch actu-
1. Remove switch as outlined in Section 6.15.1. ates at correct gauge reading.
2. Connect ohmmeter or continuity light across
8. After switch is adjusted, place a small amount of
switch terminals. Ohmmeter will indicate resis-
paint or glycerol on the adjusting screw so that
tance and continuity light will be lighted if switch
vibration will not change switch setting.
closed after relieving pressure.
3. Connect switch to a cylinder of dry nitrogen. Figure 6.16 Defrost Air Switch Test Setup
(See Figure 6.15)
4. Set nitrogen pressure regulator higher than cut-
out point on switch being tested. Pressure 2
switch cutout and cut-in points are shown in 5
Section 2.6.2.
5. Close valve on cylinder and open bleed-off
valve.
6. Open cylinder valve. Slowly close bleed-off 6 3
valve and increase pressure until the switch 4
opens. If light is used, light will go out and if an 1
ohmmeter is used, the meter will indicate open.
Open pressure on gauge. Slowly open bleed-off
valve (to decrease pressure) until switch closes 1. Ohmmeter or Continuity Device
(light will light or ohmmeter will move).
2. Adjustment Screw (0.050 socket head size)
3. Low Side Connection
6.16 Checking Calibration of the Defrost Air
4. Pressure Line or Aspirator Bulb (P/N 07-00177-01)
Switch
5. Magnehelic Gauge (P/N 07-00177)
1. Make sure magnehelic gauge is in proper calibra- 6. High Side Connection
tion.

6-23 62-11675
6.17 Evaporator Coil Cleaning 6.19 Solenoid Valves

The use of recycled cardboard cartons is increasing 6.19.1 Supra 560/660/760/860/960 3-Way Valve
across the country. The recycled cardboard cartons
create much more fiber dust during transport than new Figure 6.17 Hot Gas 3-Way Valve
cartons. The fiber dust and particles are drawn into the
evaporator where they lodge between the evaporator
fins. If the coil is not cleaned on a regular basis, some-
times as often as after each trip, the accumulation can
be great enough to restrict air flow, cause coil icing, 1
repetitive defrosts and loss of unit capacity. Due to the
washing action of normal defrost the fiber dust and par-
ticles may not be visible on the face of the coil but may
accumulate deep within. 2

It is recommended to clean the evaporator coil on a regu-

3
lar basis, not only to remove cardboard dust, but to
remove any grease or oil film which sometimes coats the
fins and prevents water from draining into the drain pan. 4

Cardboard fiber particles after being wetted and dried

several times can be very hard to remove. Therefore, 1. Snap cap
several washings may be necessary. 2. Voltage plate
3. Coil assembly
1. Remove rubber check valves (Kazoo) from drain
lines.

2. Spray coil with a mild detergent solution such as Replacing Solenoid Coil
Oakite 164 or any good commercial grade auto- It is not necessary to pump the unit down to replace the
matic dish washer detergent such as Electrosol coil. (See Figure 6.17)
or Cascade and let the solution stand for a few
minutes and re verse flush (opposite normal air 1. Remove snap cap to remove coil. Disconnect
flow) with clean water at mild pressure. A gar- from harness.
den hose with spray nozzle is usually sufficient.
2. Verify coil type, voltage and frequency. This
Make sure drain lines are clean.
information appears on the coil voltage plate
3. Run unit until defrost mode can be initiated to and the coil housing.
check for proper draining from drain pan. 3. Place new coil over enclosing tube and then
install voltage plate and snap cap.
6.18 Condenser Coil Cleaning
Replacing Solenoid Valve
Refer to Section 6.5.1.
1. Remove and store the refrigerant charge in an
evacuated container (Refer to Section 6.8).

2. Remove snap cap to remove coil.

3. Replace Valve Assembly

4. Install coil assembly, voltage plate and cap.

5. Leak check, evacuate and dehydrate the unit.

6. Install a complete refrigerant charge.

7. Start unit and check operation.

62-11675 6-24
6.19.2 Hot Gas Bypass Valve (HGS2) 4. Check for damaged plunger and o-ring. If o-ring
is to be replaced, always put refrigerant oil on o-
Figure 6.18 Hot Gas Bypass Valve (HGS2) rings be fore installing.

5. Tighten enclosing tube assembly. If the valve

1 has not been removed from the unit, leak check
2 the valve.
3 6. Install coil assembly, voltage cover and cap.

7. Evacuate and dehydrate the unit.

4 8. Install a complete refrigerant charge.

9. Start unit and check operation.

5 6.20 ADJUSTING THE COMPRESSOR PRESSURE

REGULATING VALVE (CPR)
The CPR valve is factory preset and should not need
adjustment. If it is necessary to adjust the valve for any
6 reason, proceed with the following outline.

1. Snap cap When adjusting the CPR valve, the unit must be run-
2. Voltage plate ning in the high speed heat or defrost. This will ensure
3. Coil assembly a suction pressure above the proper CPR setting.
4. Enclosing tube
Figure 6.19 Compressor Pressure Regulating
5. Plunger assembly
Valve
6. Valve body assembly
-----

Replacing Solenoid Coil:   

1. Remove coil snap cap, voltage plate and coil
assembly. Disconnect leads and remove coil
junction box if necessary.

2. Verify coil type, voltage and frequency. This

information appears on the coil voltage plate 1. Cap
and the coil housing. 2. Jam Nut
3. Setting Screw
3. Place new coil over enclosing tube and then
install voltage plate and snap cap.
-----

To adjust the CPR valve:

! CAUTION 1. Install a manifold gauge set.
Do not damage or over tighten the enclos-
ing tube assembly. Also make sure all parts 2. Remove cap (item 1) from CPR valve.
are placed on the enclosing tube in proper 3. With an 8 mm Allen wrench, loosen the jam nut
sequence to avoid premature coil burnout. (Figure 6.19 item 2).
Replacing Solenoid Valve Internal Parts: 4. Using the 8 mm Allen wrench, adjust the setting
If the valve is to be replaced or the internal parts ser- screw. To raise the suction pressure turn the set-
viced, the refrigerant charge must be removed. ting screw (item 3) clockwise; to lower the suction
pres sure, turn the setting screw counterclockwise.
1. Remove and store the refrigerant charge in an Refer to Section 2.6.3 for CPR valve setting.
evacuated container (Refer to Section 6.8).
5. When the setting has been adjusted, tighten the jam
2. Remove coil snap cap, voltage cover and coil nut securely against the setting screw (item 3). This
assembly. Remove the valve body head. will prevent any movement of the setting screw due
to vibrations in the unit. Replace the cap.
3. Check for foreign material in valve body.

6-25 62-11675
6.21 Thermal Expansion Valve (TXV) below box temperature to ensure the unit
remains in high speed cool with the unloaders
The thermal expansion valve (see Figure 6.20) is an
de-energized.
automatic device which maintains constant superheat of
the refrigerant gas leaving the evaporator regardless of 6. Note the average temperature of the suction gas
suction pressure. The valve functions are: (a) automatic at the expansion valve bulb and average pres-
response of refrigerant flow to match the evaporator load sure on the gauge.
and (b) prevention of liquid refrigerant entering the com-
pressor. During normal operation, the valve should not 7. From the temperature/pressure chart, (Table 6–
require any maintenance. If service is required, it should 6) determine the saturation temperature corre-
be performed only by trained personnel. sponding to the suction pressure.
8. Subtract the saturation temperature determined in
Figure 6.20 Thermostatic Expansion Valve step 7 from the average temperature measured in
step 6. The difference is the superheat of the suc-
tion gas. Refer to Section 2.6.3 for required setting.

1 Figure 6.21 Thermostatic Expansion Valve Bulb

and Thermocouple

4 3

2 5
2
3 4
1
1. Bulb
2. Equalizer 1. Suction Line
3. Inlet 2. TXV Bulb Champ
4. Outlet 3. Nut and Bolt
4. TXV Bulb
5. Thermocouple
Measure Superheat: -----
NOTE Replacing Expansion Valve
The expansion valve and bulb location are
located on the road side of the evaporator. 1. Check superheat in accordance with the preced-
ing steps. If valve requires replacement, pump
1. Ensure charge level is correct (refer to Section down the unit. (Refer to Section 6.8.a)
6.10.4) and ensure CPR setting is correct (refer
2. Remove insulation from expansion valve bulb
to Section 6.20).
and then remove bulb from suction line.
2. Remove insulation from expansion valve bulb
and suction line. Ensure bulb and attachment 3. Using inert gas brazing procedures (refer to
area on suction line are clean. Technical Procedure 98-50553-00), unsolder
the outlet, the equalizer and then the inlet lines
3. Place thermocouple above (parallel to) TXV to the TXV. Remove the old TXV from the unit.
bulb and then secure clamps making sure both
the bulb and thermocouple are firmly secured to 4. Using inert gas brazing procedures (refer to
suction line as shown in Figure 6.21. Reinstall Technical Procedure 98-50553-00), solder the
insulation covering both bulb and sensor. replacement valve in place.

4. Connect an accurate gauge to the 1/4 port on 5. Strap thermal bulb to suction line and insulate
the suction service valve. both. It is recommended that the thermocouple
required to check superheat be reinstalled at this
5. In order to ensure the pressure at the expansion time.
valve is stable enough for this procedure, oper-
ate the unit in high speed cooling until the box 6. Leak check and evacuate low side by connecting
temperature is below 20°F (-6.7°C). Partially at the suction and discharge service valve. Refer
block off air flow to condenser coil to raise dis- to sections 6.9 and 6.10. for general procedure.
charge pressure to 210 psig (14.8 kg/cm 2 ).
7. Re-check superheat.
Bring the setting to greater than 10 degrees
6.22 Microprocessor Controller ponents. Although the microprocessor boards are fairly
rugged when assembled, they are more fragile when
The erasable, programmable, read only memory
separated and should always be handled carefully.
(EEPROM) chip (component U3 on the microprocessor
logic board) has a label on it listing the revision level of When welding is required on the unit frame, or on the
the software. front area of the trailer, ALL wiring to the microproces-
sor MUST be disconnected. When welding is per-
formed on other areas of the trailer, the welder ground
NOTICE connection MUST be in close proximity to the area
being welded. It is also a good practice to remove both
Under no circumstances should a techni-
battery cables before welding on either the unit frame
cian electrically probe the processor at
or the truck to prevent possible damage to other com-
any point, other than the connector termi-
ponents such as the alternator and voltage regulator.
nals where the harness attaches. Micro-
processor components operate at different Replacing Key Board
voltage levels and at extremely low current
Should damage to the Key Board of the microproces-
levels. Improper use of voltmeters, jumper
sor occur, it is possible to replace only the Key Board.
wires, continuity testers, etc. could perma-
nently damage the processor. Hour Meters
As mentioned above, some microprocessor inputs The hour meter can be set to any value via the serial
operate at voltage levels other than the conventional port, if the meter has less then 5 hours on it. This
12 vdc. Connector points and the associated approxi- allows a replacement microprocessor to be set to the
mate voltage levels are listed below for reference only. same hours as the microprocessor it is replacing.
Under no circumstances should 12 vdc be applied at The microprocessor has 2 programmable maintenance
these connection points. hour meters which are set via the serial port. These
Grounded wrist cuffs are available from Carrier (P/N maintenance hour meters are compared to one of the
07-00304-00). It is recommended that these be worn hour meters (diesel, standby, or switch on). If the hour
whenever handling a microprocessor. meter is greater than the maintenance hour meter then
the proper service alarm is triggered.
Table 6–3 Connection Point Voltage
6.23 Microprocessor Replacement & Configura-
Connection Point Approximate Voltage tion
ATS, CDT, RAS, SAS, 2.5 vdc (Variable) 6.23.1 Remove & Replace Microprocessor Logic
WTS Board
MP23 5.0 vdc 1. Before removing the microprocessor, disconnect
the negative battery cable and attach a
grounded wrist strap (070030400) to your wrist
NOTICE and ground it to a good unit frame ground.
Most electronic components are suscep- 2. Open the roadside side door of the unit and
tible to damage caused by electrical loosen the 4 bolts holding the cover / micropro-
static discharge (ESD). In certain cases, cessor onto the front of the control box.
the human body can have enough static
electricity to cause resultant damage to 3. Unplug the ribbon cable from the logic board but
the components by touch. This is espe- leave it connected to the cab command cable.
cially true of the integrated circuits found 4. Take the new microprocessor from the anti-
on the truck/trailer microprocessor. static bag and install in the control box following
Although there is less danger of electrical static dis- the above steps in reverse order.
charge ESD damage in the outdoor environment, where 5. Place the removed microprocessor back into the
the processor is likely to be handled, proper board han- anti-static bag and part box for return.
dling techniques should always be stressed. Boards
should always be handled by their edges, in much the
NOTE
same way one would handle a photograph. This not only
precludes the possibility of ESD damage, but also lowers BEFORE STARTING THE UNIT: When
the possibility of physical damage to the electronic com- replacing a microprocessor it is important to
check that the configurations are compatible
with the unit into which it will be installed.

6-27 62-11675
6.23.2 Reach The Configuration Fields From b. Press either the UP or DOWN keys to display
Keypad available selections for that configuration. Leave
the correct selection on the screen. The selec-
1. Place the unit RUN/STOP Switch to the STOP tion display will flash, warning the operator that
position and the I/O Switch in the OFF position. the displayed value has not been entered. Press
2. With the unit off, locate the serial port plug the ENTER key to enter the new selection into
behind the control panel. Remove the protective memory. The display will revert to the original
cap to gain access to the wire terminals. Place selection if no further action is taken for the next
an insulated jumper wire between wires SPA five seconds.
and SPB at the serial port plug. c. Continue to scroll through the configuration list
by pressing the FUNCTION key. Change any
other configurations as required.
! CAUTION
5. When finished, turn the RUN/STOP Switch to
Do not allow this wire to touch any the STOP position, then back to the RUN posi-
ground. tion to start the unit.
3. Place the unit RUN/STOP Switch to the RUN
6.24 Controller Sensor Checkout
position and the I/O Switch in the ON position.
The FAULT light will come on, and the micro dis- An accurate ohmmeter must be used to check resis-
play will read CNF1 TV or CNF1 DI. Remove tance values shown in Table 6–5.
the jumper wire from the serial port and rein-
stall the protective cap. The configuration Due to variations and inaccuracies in ohmmeters, ther-
screen will now remain available for five min- mometers or other test equipment, a reading within 2%
utes. Scroll through the configuration list using of the chart value would indicate a good sensor. If a
the FUNCTION key and compare the settings sensor is bad, the resistance reading will usually be
with those shown in the table on the following much higher or lower than the resistance values given
page. If any of the configurations need to be in Table 6–5.
changed, continue with step 4 below.
At least one lead from the sensor (RAS, terminals D1
4. To change the configuration selection (refer to and E1 or SAS, terminals D2 and E2) must be discon-
Table 6–4): nected from the unit electrical system before any read-
ing is taken. Not doing so will result in a false reading.
a. Bring the configuration to be changed onto the Two preferred methods of determining the actual test
display. Press the ENTER key to allow change temperature at the sensor, is an ice bath at 32°F (0°C)
access to the displayed configuration. or a calibrated temperature tester.

62-11675 6-28
 Table 6–4 Configuration Codes

CONFIGRATION DESCRIPTION

Short glow cycle, 660, 760, 860 and 960 Prior to

CNF1 ON (TV)
S/N YY0000
Note 1
OFF (DI) Long glow cycle, All other units

OFF CDT not used - 860 Only

CNF2
ON CDT used - 560, 660, 760 and 960

*CNF3 OFF Max Set Point +86°F (All functions locked)

Note 3 ON Max Set Point +90°F (Modified function lock)

OFF Heat Lock out with set point < 10

CNF4
ON No Heat Lock Out

Units without unloaders

OFF
CNF5 (560, 660, 760 and 860)

ON Units with unloaders - 960 Only

OFF
CNF6
ON All units

OFF High Speed Start

Rev. 3.25 and higher only
CNF7 Low speed only engine warm-up - Not re com- Prior to Rev 3.25, Do Not Turn On
ON
mended

OFF 960 Only

CNF8
ON 560, 660, 760 and 860

*CNF9 OFF Out-of-range alarm only

Note 2 ON Out-of-range alarm and unit shut down

OFF Standby Diesel Backup is disabled. Rev. 3.23 and higher only (CNF6
CNF10
ON Enables Standby Diesel Backup. Must be ON)

*CNF11 OFF Functions changes normal

Note 3 ON Functions & Start Stop locked

OFF 560, 660, 760 and 860 Only

CNF12
ON 960 Only

OFF All units

CNF13
ON Do Not Turn On!

OFF All units

CNF14
ON Do Not Turn On!

OFF TDS (Refer to Section 2.2)

*CNF15 Rev. 3.29 and higher only
ON TDB (Refer to Section 2.2)

OFF Alt Aux alarm only

*CNF16
ON Alt Aux alarm shuts unit down

6-29 62-11675
 Table 64. Configuration Codes (Continued)

OFF UltraFreeze disabled

CNF17 Rev. 3.20 and higher only
ON UltraFreeze control on.

OFF SYSTEM CK alarm Off

CNF18 Rev. 3.20 and higher only
ON SYSTEM CK alarm On

OFF All units

CNF19
ON Do Not Turn On!

*CNF20 OFF °F / °C Unlocked

Rev. 3.23 and higher only
Note 4 ON °F / °C Locked
OFF All units
CNF21
ON Do Not Turn On!

OFF For Future Use

CNF22
ON Do Not Turn On!

OFF Set Point not Locked

CNF23 Rev. 3.29 and higher only
ON Set Point Locked

OFF WT Sensor Alarm is alarm only Rev. 3.29 and higher only
CNF24
ON WT Sensor Alarm is Unit Shutdown CNF6 Must be ON

*CNF25 ON Tier 4 Engine with air heater.

CNF26 OFF For future use. Do not turn on.

CNF27 OFF For future use. Do not turn on.

CNF28 OFF For future use. Do not turn on.

CNF29 OFF For future use. Do not turn on.

CNF30 OFF For future use. Do not turn on.

CNF31 OFF For future use. Do not turn on.

CNF32 OFF For future use. Do not turn on.

NOTE
*These settings are optional and can be set to customer specifications or left at default values. All
other settings (not marked with *) MUST be set as shown for proper unit operation.
1. CNF1 determines the length of the glow cycle, which varies depending on the type of engine in the unit. When CNF 25
is ON, the CNF1 setting is not used.

2. CNF9 allows selection of how the unit will react under an Out-Of-Range condition. An Out-Of-Range condition is
described as the box temperature having arrived at setpoint, then drifting away from setpoint. With this CNF in the OFF
position, once the box temperature has been Out-Of-Range for 15 minutes, the ALARM light will be turned on and the
alarm display OUT RANGE will be dis played alternately with the default display of the setpoint and box temperature.
With this CNF in the ON position, once the box temperature has been Out-Of-Range for 45 minutes, the unit will shut
down, and the same alarms as described above will be displayed.

3. CNF3 & CNF11:

Standard Function Lock allows the Function Key and the Start/Stop-Continuous Run Key to be locked
so that no changes can be made.
Modified Function Lock is the same as Standard Function Lock except that with the setpoint at or
between +32 and +42°F (0 and 5.6°C), the unit will always operate in Continuous Run. If the setpoint is
outside this range, either Start/Stop or Continuous Run can be selected.

62-11675 6-30
 The maximum setpoint and function lock are controlled via a combination of CNF3 and CNF11:
CNF11 OFF / CNF3 OFF: Maximum setpoint 86F (30°C) - No function lock
CNF11 ON / CNF3 OFF: Maximum setpoint 86°F (30°C) - Standard function lock
CNF11 OFF / CNF3 ON: Maximum setpoint 90°F (32.2°C) - No function lock
CNF11 ON / CNF3 ON: Maximum setpoint 90°F (32.2°C) - Modified function lock
4. CNF20 allows the Fahrenheit / Celsius function to be locked. In order to change the units setting, CNF20 must be OFF.
The units set ting can then be changed in the functional parameters list. If CNF20 is ON the units setting cannot be
changed from the functional parameters list.

6.25 Suction Pressure Transducer Table 6–5 Resistance - Micro Units (ATS,CDT, RAS,
SAS & WTS)
Before installing a new suction pressure transducer it
must be calibrated. Temperature RAS, SAS & CDT
The calibration will not be performed if the run relay is WTS Resistance Resistance
°F °C In Ohms In Ohms
energized. This prevents the operator from calibrating
the unit with the sensor in the system. The reading of -20 -28.9 165,300 1,653,000
the sensor must be at atmospheric pressure (0 psig or
14.7 psi). If the sensor reading is greater than 20 psig -10 -23.3 117,800 1,178,000
(34.7 psi) or less than -6.7 psig (8 psi) it can not be cal- 0 -17.8 85,500 855,000
ibrated. Once the micro is calibrated, the display will
readout the actual value. 10 -12.2 62,400 624,000

a. Turn power off and remove starter solenoid wire, 20 -6.7 46,300 463,000
then let unit fail to start. This will de-energize run
30 -1.1 34,500 345,000
relay.
32 0 32,700 327,000
b. Connect wiring to new suction pressure trans-
ducer. Before installing suction pressure trans- 40 4.4 26,200 262,000
ducer into unit, display the suction pressure via
50 10.0 19,900 199,000
the unit status display. While the suction pres-
sure is being displayed press Enter Key for 60 15.6 15,300 153,000
three seconds, the display should read 0. If dis-
play reads 0 install suction pressure transducer 70 21.1 11,900 119,000
into unit. 77 25 10,000 100,000

80 26.7 9,300 93,000

90 32.2 7,300 73,000

100 37.8 5,800 58,000

110 43.3 4,700 47,000

120 48.9 3,800 38,000

194 90 915 9,150

212 100 680 6,800

266 130 301 3,010

302 150 186 1,860

325 163 - 1,358

350 177 - 1,202

6-31 62-11675
 Table 6–6 R-404A Temperature - Pressure Chart

Temperature Pressure Temperature Pressure

°F °C Psig Kg/cm2 Bar °F °C Psig Kg/cm2 Bar
-40 -40 4.5 0.32 0.31 32 0 72.5 5.10 5.00
-35 -37 7.1 0.50 0.49 34 1 75.6 5.32 5.21
-30 -34 9.9 0.70 0.68 36 2 78.8 5.54 5.43
-25 -32 12.9 0.91 0.89 38 3 82.1 5.77 5.66
-20 -29 16.3 1.15 1.12 40 4 85.5 6.01 5.90
-18 -28 17.7 1.24 1.22 42 6 89.0 6.26 6.14
-16 -27 19.2 1.35 1.32 44 7 92.5 6.50 6.38
-14 -26 20.7 1.46 1.43 46 8 96.2 6.76 6.63
-12 -24 22.3 1.57 1.54 48 9 99.9 7.02 6.89
-10 -23 23.9 1.68 1.65 50 10 103.7 7.29 7.15
-8 -22 25.6 1.80 1.77 55 13 115.4 8.11 7.96
-6 -21 27.3 1.92 1.88 60 16 126.1 8.87 8.69
-4 -20 29.1 2.05 2.01 65 18 137.4 9.66 9.47
-2 -19 30.9 2.17 2.13 70 21 149.4 10.50 10.30
0 -18 32.8 2.31 2.26 75 24 162.1 11.40 11.18
2 -17 34.8 2.45 2.40 80 27 175.5 12.34 12.10
4 -16 36.8 2.59 2.54 85 29 189.6 13.33 13.07
6 -14 38.9 2.73 2.68 90 32 204.5 14.38 14.10
8 -13 41.1 2.89 2.83 95 35 220.2 15.48 15.18
10 -12 43.3 3.04 2.99 100 38 236.8 16.65 16.33
12 -11 45.6 3.21 3.14 105 41 254.2 17.87 17.53
14 -10 48.0 3.37 3.31 110 43 272.4 19.15 18.78
16 -9 50.4 3.54 3.47 115 46 291.6 20.50 20.11
18 -8 52.9 3.72 3.65 120 49 311.8 21.92 21.50
20 -7 55.5 3.90 3.83 125 52 332.9 23.41 22.95
22 -6 58.1 4.08 4.01 130 54 355.0 24.96 24.48
24 -4 60.9 4.28 4.20 135 57 378.1 26.58 26.07
26 -3 63.7 4.48 4.39 140 60 402.3 28.28 27.74
28 -2 66.5 4.68 4.59 145 63 427.6 30.06 29.48
30 -1 69.5 4.89 4.79 150 66 454.0 31.92 31.30

62-11675 6-32
 SECTION 7
Troubleshooting

! CAUTION
DO NOT attempt to service the microprocessor or the logic or display boards! Should a prob-
lem develop with the microprocessor, contact your nearest Carrier Transicold dealer for
replacement.

7.1 Diesel Engine

Indication / Troubles Possible Causes Reference

Sections

7.1.1 Engine Will Not Start

Starter motor will not crank or low Battery insufficiently charged Check
cranking speed Battery terminal post dirty or defective Check
Bad electrical connections at starter Check
Starter motor malfunctions 7.1.3
Starter motor solenoid defective Engine Manual
Open starting circuit 7.1.4
Incorrect grade of lubricating oil 2.6

Starter motor cranks No fuel in tank Check

but engine fails to start Air in fuel system Check
Water in fuel system Drain Sump
Plugged fuel filters Replace
Plugged fuel lines to injector (s) Check
Fuel control operation erratic Engine Manual
Glow plug(s) defective •
Run solenoid defective
Fuel pump (FP) malfunction 6.5.4

Starter cranks, engages, Engine lube oil too heavy 2.6

but dies after a few seconds Voltage drop in starter cable(s) Check

7.1.2 Engine Starts Then Stops

Engine stops after Fuel supply restricted Check

several rotations No fuel in tank Fill Tank
Leak in fuel system Repair
Faulty fuel control operation Engine Manual
Fuel filter restricted 6.5.4
Injector nozzle(s) defective Engine Manual
Injection pump defective Engine Manual
Air cleaner or hose restricted 6.5.3
Safety device open 2.7
Open wiring circuit to run solenoid
Fuel pump (FP) malfunction 6.5.4

7-1 62-11675
 7.1.3 Starter Motor Malfunction

Starter motor will not Battery insufficiently charged Check

crank or turns slowly Battery cable connections loose or oxidized Check
Battery cables defective Replace
Starter brushes shorted out Engine Manual
Starter brushes hang up or have no contact Engine Manual
Starter solenoid damaged Engine Manual
I/O or START/RUN Switch defective Replace
Engine lube oil too heavy 2.6.1

Starter motor turns Pinion or ring gear obstructed or worn Clean both, re-
but pinion does not engage move burrs, or
replace; apply
grease

Starter motor does not disengage I/O or START/RUN Switch defective Replace
after switch was depressed Starter motor solenoid defective Engine Manual

Pinion does not disengage Defective starter Engine Manual

after engine is running

7.1.4 Malfunction In the Engine Starting Circuit

No power to starter Battery defective Check

motor solenoid (SS) Loose electrical connections Tighten

Run solenoid Battery defective Check

does not energize or does Loose electrical connections Tighten
not remain energized
Oil pressure safety switch (OP) defective Replace
Run relay (RR) defective Replace
Water temperature safety switch open 2.7
Water temperature sensor (WTS) defective Replace
Run solenoid defective
I/O or START/RUN Switch defective Replace

7.2 Alternator (Automotive Type)

Alternator fails to charge Limited charging system operating time Check

Battery condition Check
Alternator belt loose/broken 6.6
Loose, dirty, corroded terminals, or broken leads Check/Repair
Excessively worn, open or defective brushes Check
Open blocking diode Check
Regulator faulty Check
Open isolation diode Check
Open rotor (field coil) Replace

Low or unsteady charging rate Alternator belt loose 6.6

Loose, dirty, corroded terminals, or broken leads Check/Repair
Excessively worn, sticky or intermittent brushes Check
Faulty regulator Check
Grounded or shorted turns in rotor Check
Open, grounded or shorted turns in stator Replace

62-11675 7-2
Excessive charging rate Regulator leads loose, dirty, corroded terminals, or wires Clean/Repair
(as evidenced by battery broken Check
requiring too frequent refilling) or Defective regulator
charge indicator shows constant
charge with engine idling

Noisy alternator Defective or badly worn V-belt 6.6

Worn bearing(s) Replace
Misaligned belt or pulley 6.6
Loose pulley Tighten

7.3 Refrigeration

7.3.1 Unit Will Not Cool

Diesel engine Malfunction(s) 7.1

Compressor malfunction Compressor drive defective 6.11

Compressor defective 6.11

Refrigeration system Defrost cycle did not terminate 7.3.5

Abnormal pressure 7.3.6
Hot Gas 3-way valve malfunction 7.3.11

7.3.2 Unit Runs But Has Insufficient Cooling

Compressor Compressor valves defective 6.11

Unloader malfunction 6.13

Refrigeration system Abnormal pressure 7.3.6

Expansion valve malfunction 7.3.10
No or restricted evaporator airflow 7.3.9
Unloader malfunction 6.13

Engine does not Speed control linkage

develop full rpm Engine malfunction 7.1

7.3.3 Unit Operates Long or Continuously in Cooling

Container Hot Load Allow time to pull

Defective box insulation or air leak down
Correct

Refrigeration system Abnormal pressure 7.3.6

Temperature controller malfunction 7.3.8

Compressor Defective 6.11

7.3.4 Unit Will Not Heat or Has Insufficient Heating

Refrigeration Abnormal pressure 7.3.6

Temperature controller malfunction 7.3.8
Hot Gas 3-way valve malfunction 7.3.11

Compressor Compressor drive defective 6.11

Compressor defective 6.11

Engine does not develop Speed control linkage

full rpm Engine malfunction 7.1

7-3 62-11675
7.3.5 Defrost Cycle Malfunction

Will not initiate defrost Defrost air switch (DA) out of calibration 6.16
automatically Defrost thermostat (DTT) open or defective Replace
Defrost air switch (DA) defective 6.16
Loose terminal connections Tighten
Air sensing tubes defective or disconnected Check

Will not initiate defrost manually Microprocessor defective Replace

Loose terminal connections Tighten
Defrost thermostat (DTT) open or defective Replace

Initiates but does not defrost Hot Gas 3-way valve malfunction 7.3.11
Defrost relay (DR) defective Replace
Evaporator Clutch defective Replace

Frequent defrost Defrost air switch (DA) out of adjustment 6.16

Wet load Normal

Does not terminate or Defrost thermostat (DTT) shorted closed Replace

cycles on defrost Defrost air switch (DA) out of adjustment 6.16

7.3.6 Abnormal Pressure, Cooling

High discharge pressure Quench valve malfunction Replace

Condenser coil dirty 6.18
Condenser fan defective Check
V-belt broken or loose 6.6
Discharge check valve restricted Replace
Non-condensibles or refrigerant overcharge Replace

Low discharge pressure Compressor valve(s) worn or broken 6.11

Hot Gas 3-way valve malfunction 6.19.1

High suction pressure Compressor valve(s) worn or broken 6.11

Compressor gasket(s) defective 6.11
Hot Gas (three-way) valve malfunction 6.19.1

Low suction pressure Suction service valve partially closed Open

King valve partially closed Open
Filter-drier partially plugged 6.14
Low refrigerant charge 10.
Expansion valve malfunction 7.3.10
No evaporator air flow or restricted air flow 7.3.9
Excessive frost on coil Check

Suction and discharge Compressor valves defective 6.11

pressures tend to equalize Hot Gas 3-way valve malfunction 6.19.1
when unit is operating

62-11675 7-4
7.3.7 Abnormal Pressure, Heating

High discharge pressure Overcharged system 6.10.4

Condenser fan defective Check
V-belts broken or loose 6.6
Non-condensibles in system Check

Low discharge pressure Compressor valve(s) worn or broken 6.11

Hot Gas 3-way valve malfunction 6.19.1
Low refrigerant charge 10.

Low suction pressure Refrigerant shortage 10.

Compressor pressure regulating valve malfunction 6.20
Suction service valve partially closed Open

7.3.8 Abnormal Noise

Compressor Loose mounting bolts Tighten

Worn bearings 6.11
Worn or broken valves 6.11
Liquid slugging 7.3.10
Insufficient oil 6.12

Condenser or Loose or striking shroud Check

evaporator fan Bearings defective Check
Bent shaft Check

V-belts Cracked or worn 6.6

7.3.9 Control System Malfunction

Will not control Sensor defective 6.24

Relay(s) defective Check
Microprocessor controller malfunction 6.22
Solid State controller malfunction Replace

7.3.10 No Evaporator Air Flow or Restricted Air Flow

Evaporator coil blocked Frost on coil Check

Dirty coil 6.17
Fan motor(s) malfunction Replace

No or partial evaporator V-belt broken or loose 6.6

air flow Clutch defective Replace
Evaporator fan loose or defective Check
Evaporator fan rotating backwards Check
Evaporator air flow blocked in trailer (box) Check
Fan motor(s) malfunction Replace

7-5 62-11675
7.3.11 Expansion Valve Malfunction

Low suction pressure with Low refrigerant charge 6.9 / 10.

high superheat External equalizer line plugged Clean
Ice formation at valve seat 6.10
Wax, oil or dirt plugging valve or orifice 6.21
Broken capillary 6.21
Power assembly failure or partial Replace
Loss of element/bulb charge Replace
Superheat setting too high 6.21

Low superheat and liquid Superheat setting too low 6.21

slugging in compressor External equalizer line plugged Open
Ice holding valve open 6.10
Foreign material in valve Clean
Pin and seat of expansion valve eroded or held open by 6.21
foreign material

Fluctuating suction Improper bulb location or installation 6.21

pressure Low superheat setting 6.21

High superheat Broken capillary 6.21

7.3.12 Hot Gas (3-Way) Valve Malfunction

Valve does not function properly No power to valve Check

Improper wiring or loose connections Check
Coil defective 6.19.1
Valve improperly assembled 6.19.1
Coil or coil sleeve improperly assembled 6.19.1
Temperature controller malfunction Replace
Movement of plunger restricted due to: 6.19.1
Corroded or worn parts
Foreign material lodged in valve
Bent or dented enclosing tube

Valve shifts but refrigerant Foreign material lodged under seat 6.19.1
continues to flow Defective seat 6.19.1

7.4 Standby Motor Malfunction

Standby motor fails to start Motor contactor (MC) defective Replace

Motor Overload (OL) open Replace motor
Improper power supply 2.6.4
Oil pressure switch (OPS) open Check
Cab Command defective Replace

Standby motor starts, then stops Motor Overload (OL) open 2.6.4
High amperage draw Check

62-11675 7-6
 SECTION 8
Electrical Schematic Wiring Diagram
8.1 Introduction

NOTE
All illustrations provided in this Section are looking at the connector connection end (with the wires in
the back).

! WARNING
Beware of unannounced starting of the fans and V-belts caused by the thermostat and the
start/stop cycling of the unit.

! WARNING
Under no circumstances should ether or any other starting aids be used to start engine.

! CAUTION
Under no circumstances should anyone attempt to repair the Logic or Display Boards! Should
a problem develop with these components, contact your nearest Carrier Transicold dealer for
replacement.

! CAUTION
Observe proper polarity when installing battery, negative battery terminal must be grounded.
Reverse polarity will destroy the rectifier diodes in alternator. As a precautionary measure, dis-
connect positive battery terminal when charging battery in unit. Connecting charger in reverse
will destroy the rectifier diodes in alternator.

NOTICE
Under no circumstances should a technician electrically probe the processor at any point,
other than the connector terminals where the harness attaches. Microprocessor components
operate at different voltage levels and at extremely low current levels. Improper use of voltme-
ters, jumper wires, continuity testers, etc. could permanently damage the processor.

NOTICE
Most electronic components are susceptible to damage caused by electrical static discharge
(ESD). In certain cases, the human body can have enough static electricity to cause resultant
damage to the components by touch. This is especially true of the integrated circuits found on
the truck/trailer microprocessor.

8.2 Wiring Schematic

The wiring schematics are provided on the following pages.

8-1 62-11675
 wiring schematics

Correction: WHITE =
DC Control Circuits

BASED ON DRAWING 62ï04126

Figure 8-1. Electrical Schematic Wiring Diagram (Sheet 1 of 2)

62-11675
 BASED ON DRAWING 62ï04126

Figure 8-2. Electrical Schematic Wiring Diagram (Sheet 2 of 2)

62-11675
8-3 62-11675
 WARNING: Breathing diesel engine
exhaust exposes you to chemicals known to
the State of California to cause cancer and
birth defects or other reproductive harm.

x Always start and operate the engine in a

well-ventilated area.
x If in an enclosed area, vent the exhaust to
the outside.
x Do not modify or tamper with the exhaust
system.
x Do not idle the engine except as
necessary.

For more information, go to

www.P65warnings.ca.gov/diesel

North America Central America and Mexico

Carrier Transicold Ejercito Nacional 253−A Piso 5
700 Olympic Drive Colonia Anahuac
Athens, GA 30601 USA 11320 Mexico, D.F.
Tel: 1-706-357-7223 Tel: 55315010
Fax: 1-706-355-5435 Fax: 55315010 ext. 1005

Carrier Transicold
P.O. Box 4805
Syracuse, NY 13221 USA
A part of UTC Building & Industrial Systems, a business unit of
United Technologies Corporation. Stock Symbol UTX. www.carrier.transicold.com